Shutdown and Turnaround Management

Planning and managing shutdowns, turnarounds and outages in the process plant environment is a complex and demanding function. Because of the high combined costs and potential impact (both positive and negative) on the business, shutdowns can have intense top management attention. Because of the cost, impact, and attention, these events are more intensively managed than other large maintenance jobs. This aspect has both good and bad (from a shutdown management perspective) results. On the good side, resources are usually easier to come by. On the negative side, we can see excessive top management meddling. Like military actions, professionals should run shutdowns. If turnarounds are not properly planned, managed and controlled, companies run the risk of serious budget overruns, costly schedule delays and negative impacts on customers. This program, includes the core planning technique and cost control applied to the shutdown and turnaround environment and introduces participants to the full range of best practices techniques and knowledge.

Audience

This course is designed for:

Operations and maintenance engineers
Maintenance Managers
Engineers, supervisors and qualified senior technicians
Planning managers, engineers, planners and qualified assistance planners
Production managers, engineers, supervisors and qualified senior operators

Course objectives

The program’s principal objectives are:

The management of overall shutdown phases.
How to develop the scope of work and Planning Techniques.
Case Study of oil /gas shutdown plan.
How to prepare work package for each individual job.
Effective workforce management and organization.
Shutdown production operation.
Costs & Contractors optimum control.
Management the execution in the face of reality.
HSE Management System and Manage risks.
Measurement and reporting the progress
Reporting the completion /completion /close
Preparation for startup

Course contents

Day-1

Input to shutdown
Definitions

– Basics of Shutdowns, Turnarounds, and Outages

– Different between Shutdown, Turnarounds and outages

– Size of the Shutdown

– Different between Project and Turnaround

– Turnaround/Shutdown Communications

– Turnaround/Shutdown Phases

How to justify the Turnaround / Shutdown
Turnaround/Shutdown Organization
Master Schedule for Phase 1 Initiation
Shutdown/Turnaround Planning

– Typical Story of maintenance planning (Case Study)

– Definitions and Reasons for a Planning

Day-2

Shutdown/Turnaround Planning…continue

– CMMS as a tool

– Scope of Work: How to Find and Pick the Jobs

. Sources of shutdown work

. Formalize the walk down tour

. Prioritize other work for the shutdown

. Position yourself for the future

– Work Validation and preparation for planning

– Validation Process

– Packaging

– Individual Job Planning

– Case Study for scope of work preparation

Planning Techniques

– Project Management

– Key concepts for all PM techniques

– Planning, monitoring and control

– Internal Progress meetings

– Projects Boundaries

– Critical Path Method (CPM)

– Resources

– PERT and newer methods

– PM (Project Management) Software

Day-3

Understand Hazards & Risks
Manage Risks
Causes of Equipment Failure
Master Schedule for phase 2 planning
Shutdown Essentials

– Contractors:

. Contracts & Outsourcing Strategy & Contractor Management

. How to integrate external organizations

– Budgets & Costs control

– Logistics

. Spare parts Management

. Organization for the parts, materials and supplies

Case Study – Oil/Gas Shutdown Plan using MS-Project Software
Shutdown Execution & production operation
Execution (How to manage in the face of reality)
Production Shutdown /Turnaround Planning
Shutdown/Turnaround operation and safety procedures
Equipment or section isolation

. Type of Isolations

. Isolation reporting

. Mechanical Isolation Detailed Sheet

. Major Isolations

. Electrical Isolations

. Safety Lock-off Systems

. Case Study

Day-4

Shutdown Execution & production operation…..continue
Particular consideration when pressurizing and depressurizing vessels
Master Schedule for Phase 3 Execution
KPI’s
Follow up inspection reports & modification
Progress reports
Completion Phase
Completion
Reporting
Close Out

Day-5

Master Schedule for Phase 4 and Phase 5
Start-up
Potential problems during the start-up operation
Staffing and Equipment/Materials required for plant startup
General Start-up preparation
Start-up Planning
Machinery Start-up operation
Static Equipment Start-up operation
Utility Start-up operation
Process Start-up operation

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