Managing Shutdowns, Turnarounds, and Outages: Best Practices and Strategies

Introduction:

Effectively planning and managing shutdowns, turnarounds, and outages in a process plant environment is both intricate and crucial. These operations significantly impact a plant's efficiency and can have severe consequences if not executed properly. Addressing challenges such as budget overruns, scheduling delays, and negative customer impacts is essential for successful management.

This Shutdowns, Turnarounds, and Outages Training Course is designed to equip participants with the skills and knowledge needed to manage these complex operations efficiently.

Objectives:

By the end of this Shutdowns, Turnarounds, and Outages Management Training, participants will be able to:

• Enhance the organization’s turnaround management capabilities through effective planning for plant shutdowns and turnarounds.
• Acquire a thorough understanding of turnaround management principles and their practical application.
• Apply strategic planning techniques and advocate for a collaborative approach to achieve turnaround goals and objectives.
• Integrate new technologies and advanced practices in turnaround planning and management.
• Streamline turnaround processes to minimize stress and conflict while ensuring effective planning and execution.

Training Methodology:

• Instrumental case studies
• Work simulations and role-play
• Webinars
• Guest lectures
• Teamwork

Course Outline:

Unit 1: The Basics of Shutdown and Turnaround Management

• Overview and introduction to shutdowns and turnarounds
• Strategy development for shutdown planning
• Discussion of common issues and concerns
• Organization and execution of management strategies

Unit 2: Steps Toward a Successful Shutdown/Turnaround

• Plant shutdown procedures for maintenance
• Establishing scope of work and work breakdown structure
• Organizational structures and roles to enhance management

Unit 3: Further Planning Considering Shutdowns and Turnarounds

• Developing a comprehensive shutdown and turnaround plan
• Utilizing Critical Path Planning Techniques
• Short-cut planning methods
• Managing scheduling for overlapping or conflicting projects

Unit 4: Costs, Control, and Use of Contractors in Shutdowns

• Developing shutdown-specific budgets
• Controlling project execution, budget, and productivity reporting
• Planning and controlling materials
• Managing contractors during shutdowns

Unit 5: Focus on Safety, Quality, and Risk Management

• Implementing safety, quality, and environmental management practices
• Minimizing risk through mitigation strategies
• Incorporating risk management into the overall shutdown plan
• Reviewing lessons learned and concluding the course