ICTD International Centre for Training and Development

Process Plant Shutdown, Turnaround and Maintenance Management

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About the course

In the process industry, shutdown and turnaround costs are responsible for an excessive amount of maintenance expenses. Process Plants Shutdown and Turnaround Maintenance and Management explores various types of shutdowns, presents recommendations for better management and offers feasible solutions to help reduce overheads.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

  • Develop a shutdown and turnaround strategy and maintenance
  • Manage of all stages of the shutdown process
  • Develop an action plan to improve turnaround management techniques
  • Discuss different types of shutdown and managing events such as emergency, planned, unplanned and turnaround) and cover all aspects of plant turnaround management including startup, shutdown and maintenance.
  • Describe the five phases of shutdown management that includes initiating, planning, executing, controlling and closing

Course Outline

Day 1

  • Introduction
  • Process Plant Turnarounds
  • Activities during a Turnaround
  • Maintenance Philosophy
  • Economics of Maintenance Management
  • Types of Maintenance Activities
  • Types of Shutdown
  • Shutdown of Key Refinery Units Affecting Product Pattern
  • Strategic Issues
  • Turnaround Evaluation

Initiating the Turnaround

  • Initiation
  • Developing a Shutdown Overview
  • Strategic Plan
  • Establish Shutdown Charter
  • Initiating
  • Scope Statement
  • Appoint Shutdown Team
  • Major Turnaround Milestones
  • What Are the Shutdown/Turnaround Performance Criteria?

Planning

  • Kickoff Meetings
  • Job of Planning Team
  • Planning Step One: Developing the Shutdown Work List
  • Planning Step Two: Identify Task Relationships
  • Planning Step Three: Manpower Strategic Planning
  • Planning Step Four: Estimate Work Packages
  • Planning Step Five: Calculate an Initial Schedule
  • Planning Step Six: Assign and Level Resources
  • Planning Step Seven: Develop Procurement Plan
  • Planning Step Eight: Develop Quality Plan
  • Planning Step Nine: Develop Communications Plan
  • Planning Step Ten: Develop Risk Plan
  • Checklist
  • Information Requirements for Planning
  • Planning Is Not a One-Time Event!

Estimating

  • What Is an Estimate?
  • Methods for Estimating Activity Duration
  • What Is the Cost Baseline?

### Day 2

Shutdown Contract Management

  • What Is a Contract?
  • Scope of a Contract
  • Parties to a Contract
  • Objectives
  • Contractors
  • Selection of Contractor Work Packages
  • Contract Types
  • Selection of Contractor
  • Tender Evaluation Practices
  • Management of Obviously Low Bids
  • Subcontracts
  • Terms of Payment
  • Logistics

Shutdown Organization

  • What Is Involved in Effective Shutdown Organization?
  • Turnaround Steering Committee
  • Determination of the Skills Needed
  • Shutdown Manager’s Skill Requirement
  • Leading

Executing the Shutdown

  • The Kickoff Meeting
  • Safety
  • Job Status Update
  • Daily Schedule
  • Reporting Status
  • Tracking Shutdown Costs

Preshutdown Job

  • Long-Delivery Items
  • Checklist
  • Preshutdown
  • Prefabricated Work
  • Accommodation and Facilities
  • Crowd Control
  • Contractor’s Insurance Certificates
  • Safety Training
  • Employing Barricades
  • Emergency Showers and Eyebaths
  • Special Machines
  • Vendors Representatives

### Day 3

Inspection of Equipment

  • Traditional Inspection Practice: Background
  • Inspection of Equipment
  • Columns
  • Vessels
  • Heat Exchangers
  • Demister Pad
  • Refractory
  • Pressure Safety Valves
  • Inspection during Fabrication of New Piping
  • External Corrosion
  • Approaches for Other Equipment Types

Shutdown Safety

  • Hazardous Chemicals and Catalysts
  • Common Hazards
  • Safety Planning
  • Safety Preplanning
  • Evaluation and Selection of Contractors and Subcontractors
  • Emergency Warning System and Procedures

Communication Package

  • Methods of Communicating
  • Conducting Meetings
  • Communication for Success

Shutdown Control

  • What Are You Actually Controlling?
  • What Are the Baselines?
  • Measuring Progress

Day 4

Quality Plan

  • Shutdown Quality
  • Deliverable Quality
  • Planning Quality

Risk in Shutdown

  • Why Risk Analysis Is Necessary
  • What Is Risk Management?
  • What Are the Basic Steps in Risk Management?
  • What Is Risk Identification?
  • What Is Risk Quantification?
  • What Are Risk Response Strategies?
  • Why Do We Have Two Separate Reserves to Take Care of the Risks?
  • Using a Risk Profile
  • Historical Records

Joint Integrity

  • Managing Integrity
  • Major Causes of Joint Leakage
  • Corrective Action for Guideline and Responsibility Deficiencies
  • Joint Assembly Procedure
  • Conclusion

### Day 5

Commissioning

  • Systematic Commissioning Planning
  • Mechanical Integrity
  • What to Do in Checklisting
  • Commissioning
  • Process Commissioning
  • Commissioning and Start-Up Period
  • Minimum Facilities before Start-Up
  • Pre-Start-Up Safety Review (PSSR)
  • Customized Testing and Acceptance Methodologies
  • Sequence of Commissioning
  • Equipment Operating Procedures

Postshutdown Review

  • Contract Closure
  • Administrative Closure
  • Post evaluation Report
  • Safety/Environmental Performance and Procedures
  • Shutdown File
  • Final Report
  • Lesson Learned Session
  • Celebrating

Performance

  • Performance Measure; Success
  • Lean Shutdowns: Cut Waste Wisely from Your Outages

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

Who should attend

This course is intended for 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 and participation from inspection, materials, safety and maintenance engineering is also encouraged.

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