Managing Efficient Shutdowns & Turnarounds

Managing Efficient Shutdowns & Turnarounds

OBJECTIVES

• To enhance the company’s turnaround management capabilities, and to ensure a team approach in the planning and execution of plant shutdowns and turnarounds
• Provide a comprehensive understanding of effective turnaround management techniques and implementation
• Create awareness of planning methods and an integrated organizational approach in the execution of successful turnarounds
• Incorporate latest developments in turnaround planning and management techniques and emerging industry trends
• Develop an action plan to improve their own turnaround management techniques
• Have a much clearer understanding of their own and every other team members role in ensuring a successful turnaround

 WHO SHOULD ATTEND?

• Shutdown or turnaround professionals and coordinators
• Planning/scheduling and cost control staff
• Construction superintendents and supervisors
• Operations shutdown/outage coordinators
• Project engineers and contract administrators
• Participation from inspection, materials, safety and maintenance engineering is also encouraged

COURSE OUTLINE

DAY 1

The Role of Maintenance Shutdowns and Turnarounds in World-class Organizations

• How shutdowns and turnarounds can contribute to the business
• Key success factors
• The three critical paths of shutdowns and turnarounds
• The difference between shutdowns and turnarounds and projects
• Shutdown and turnaround return on investment
• Shutdown and turnaround management self-assessment
• The shutdown and turnaround phases
• Reasons for shutdowns and turnarounds
• Success Factors

DAY 2

Shutdown/Turnaround Preparation

• Risk management
• Justification requirements
• Communications to stakeholders
• Shutdown roles and organization
• RASCI matrix for shutdown
• Preparation critical success factors
• Identify routine PM to be included in scope
• Identify routine condition based tasks to be performed prior to shutdown and turnaround
• Identify function testing to be performed at conclusion of shutdown and turnaround

DAY 3

Shutdown/Turnaround Preparation continued

• Apply CBM and degradation analysis to create scope visibility
• Apply notification process to manage create scope visibility
• Apply risk-based task selection methods to priorities and challenge scope
• Review, approve, communicate and freeze the scope
• The critical outcomes of planning
• The 5 Ms of maintenance work quality
• Job analysis and scoping
• Estimating
• Risk and contingency planning
• The use of planning templates
• Work breakdown structure

DAY 4

Shutdown and Turnaround Schedule

• Terms and concepts of scheduling
• Network display methods
• Apply CPM
• Identify resource constraints
• Resource requirements based on CPM
• Resource smoothing
• Resource balancing
• Optimized resource profile
• Shutdown and turnaround budgets
• Assign Shutdown Work – In-house and Contractors
• Types of contractors
• Types of contracts and criteria for selection
• Risks associated with the use of contractors
• Benefits of using contractors on shutdowns
• Staying in control of the contractor

DAY 5

Shutdown and Turnaround, Execution Control and Review

• The shutdown package
• Shutdown quality control
• Shift schedules
• Preparing equipment for the shutdown
• Daily schedules
• Dealing with emergent and additional Work
• Control data
• Status accounting
• Control the Shutdown
• S-curves
• Earned-value
• Shutdown performance indicators
• Shutdown and turnaround review meeting agenda
• Why shutdowns fail
• Problems in shutdowns and their origins
• Start-up and commissioning
• Shutdown close-out reporting and review
• Shutdown closing out report
• Shutdown closing out review
• Overview of computerized tools