Efficient and Safe Plant Shutdown and Turnarounds Management
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Efficient and Safe Plant Shutdown and Turnarounds Management Course
Introduction:
The planning and management of shutdowns, turnarounds, and outages in a process plant environment is a complex and challenging undertaking. Due to the significant combined costs and potential impact on the business, these events often receive significant attention from top management. Consequently, shutdowns are subject to more intensive management compared to other large maintenance projects. This aspect yields both positive and negative outcomes from a shutdown management perspective.
On the positive side, resources are typically more readily available. However, on the negative side, excessive meddling from top management can occur. Similar to military operations, shutdowns should be entrusted to professionals with expertise in this area. Inadequate planning, management, and control of turnarounds can result in substantial budget overruns, costly schedule delays, and adverse effects on customers. This program encompasses essential planning techniques and cost control strategies specific to the shutdown and turnaround environment. Participants will be introduced to a comprehensive range of best practices, techniques, and knowledge in this field.
Course Objectives:
The program’s principal objectives are:
- The management of overall shutdown phases.
- How to develop the scope of work and Planning Techniques.
- Case Study of oil /gas shutdown plan.
- How to prepare a work package for each individual job.
- Effective workforce management and organization.
- Shutdown production operation.
- Costs & Contractors optimum control.
- Management the execution in the face of reality.
- HSE Management System and Manage risks.
- Measurement and reporting the progress
- Reporting the completion /close up
- 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
- Preparation for startup
Who Should Attend?
Maintenance Managers, Engineers, Supervisors and qualified senior technicians. Planning Managers, Engineers, planners and qualified assistance planners. Production Managers, Engineers, Supervisors and qualified senior operators. Also, this training 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 Outlines:
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
Shutdown / Turnaround Preparation
- Risk Management
- Justification Requirements
- Communications to Stakeholders
- Shutdown Roles and Organization
- RASCI Matrix for Shutdown
- Preparation of 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
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 Prioritise 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
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
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