Efficient Shutdown and Turnaround Management

Introduction

Managing closures, maintenance, and overhauls in a process plant involves complex and often challenging tasks. Effective management requires meticulous planning and coordination to mitigate risks and ensure all aspects are addressed. Without proper management, these activities can lead to severe budget overruns, delays, and reduced customer satisfaction.

Objectives

By the end of the Efficient Turnaround and Shutdown Management course, participants will be able to:

• Enhance the company's turnaround management capabilities and promote the use of cross-functional project teams in planning and executing plant shutdowns and turnarounds.
• Explain the methods involved in shutdown and turnaround management in detail.
• Recognize integrated strategic resource management and planning for managing downtime, turnarounds, and outages.
• Utilize recent advances and new concepts in turnaround planning and management.
• Develop an actionable plan for improving turnaround management processes at their sites.
• Understand the roles and responsibilities in achieving successful shutdowns and turnarounds.

Training Methodology

• Work-Based Learning
• Project-Based Learning
• Inside and Outside Class Activities
• Experiential Learning
• Performance Simulation
• Case Study
• Panel Discussion
• Team-Based Learning

Course Outline

Unit 1: A Maintenance Shutdown and Turnaround: Their Function in World-Class Organizations

• The business value of Shutdowns and Turnarounds
• Key Success Factors
• The Three Critical Paths for Successful Shutdowns and Turnarounds
• Differentiating Shutdowns and Turnarounds from Projects
• Return on Investment for Shutdowns and Turnarounds
• Self-Management Appraisal: Shutdown and Turnaround Management
• Phases of Shutdown and Turnaround
• Causes and Success Factors

Unit 2: Pre-Shutdown/Turnaround Major Activities

• Risk Responsibility and Measurement
• Justification Requirements
• Communication with Stakeholders
• Defining Organizational Shutdown Roles
• RASCI Matrix for Shutdown
• Preparation Success Factors
• Identifying RC PM and Tasks Before Shutdown and Turnaround
• Functional Testing Post-Shutdown and Turnaround

Unit 3: Continued Pre-Shutdown/Turnaround Activities

• Using CBM and Degradation Analysis for Scope Visibility
• Applying Scope Visibility Management Early in Notification
• Risk-Based Task Selection for Prioritization and Scope Challenges
• Scope Review and Approval
• Key Aspects of Planning
• Work Quality of Maintenance Process (The 5 Ms)
• Job Analysis, Job Scoping, and Cost Estimation
• Risk Management and Contingency Plans
• Planning Templates and Work Breakdown Structure

Unit 4: Shutdown and Turnaround Scheduling

• Basic Scheduling Concepts and Terms
• Network Display Methods
• Applying CPM Concept
• Resource Constraints and Requirements
• Balancing Resource Supply and Demand
• Marketable Resources Work Profile
• Shutdown and Turnaround Costs
• Internal Contractors vs. Outsourcing
• Contractor Selection Criteria and Issues
• Contractor Control

Unit 5: Shutdown and Turnaround Execution Control

• Description of the Shutdown Package
• Quality Control during Shutdown
• Shift Patterns and Equipment Readiness
• Daily Timetable and Managing Extra Work
• Data for Operational Control
• Status Accounting and Shutdown Control
• S Curves and Earned Value Metrics
• Shutdown Performance Metrics and Review Meetings
• Causes of Unsuccessful Shutdowns
• Completion Report and Reviewing
• Implementation of Computerized Tools