Managing Efficient Shutdown and Maintenance

Planning and managing shutdowns, turnarounds and outages in the process plant environment is a complex and demanding function.

If turnarounds are not properly planned, managed and controlled, companies run the risks of serious budget overruns, costly schedule delays and negative impacts on customers.

In this program you will learn:

• How to develop a Shutdown/Turnaround strategy
• Management of all stages of the shutdown process
• Develop the management plan, work plans, resource plans and budget
• How to management related issues such as risk and safety

Course Objectives

Upon successful completion of this course, the delegates will be able 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 turnarounds 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 member role in ensuring a successful turnaround

Who Should Attend?

The course would undoubtedly be of immense value and interest to 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
• Reason for shutdowns and turnarounds
• Success Factors

Day 2
Shutdown/Turnaround Preparation

• Risk Management
• Justification requirements
• Communications to Stakeholders
• Shutdowns roles and organizations
• RASCI Matrix for Shutdown
• Preparation Critical Success Factors
• Identify Routine PM to be included in scope
• Identify Routine condition based task to be performed prior to Shutdown and Turnaround
• Identify function testing to be performed at conclusion of Shutdown and Turnaround
• Apply CBM and degradation analysis to create scope visibility
• Apply notification process to manage create scope visibility
• Apply risk-based task selection methods to prioritize and challenge scope
• Review, approve, communicate and freeze the scope
• The critical outcomes of planning
• The 5M's of maintenance work quality
• Job Analysis and Scoping
• Estimating
• Risk and contingency planning
• The use of planning templates
• Work breakdown structure

Day 3
Shutdown and Turnarounds 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 Turnarounds budgets
• Assign shutdown work – In-house and Contractors
• Types of contractors
• Types of contractors and criteria for selection
• Risks associated with the use of contractors
• Benefits of using contractors on shutdowns
• Staying in Control of the Contractor

Day 4
Shutdown and Turnarounds, 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

Day 5
Shutdown and Turnarounds, Execution Control and Review (cont’d)

• Shutdown and Turnarounds review meeting agenda
• Why shutdowns fail
• Problems in shutdown 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

Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation

Course Fees

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings

Daily Course Timings
08:00 - 08:20       Morning Coffee / Tea
08:20 - 10:00       First Session
10:00 - 10:20       Coffee / Tea / Snacks
10:20 - 12:20       Second Session
12:20 - 13:30       Lunch Break & Prayer Break
13:30 - 15:00       Last Session