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
- Conclusion