Objectives of the Course

The shutdown of Plants for major turnaround is an essential O&M requirement to ensure plant integrity and healthy safety systems, execute major revamps and plant upgrading, meet Regulatory requirements for inspection, ensure plant performance and productivity. However plant shutdown involve production losses and hefty costs, for resources and material, to do the turnaround. This course objective is to execute the turnaround in a professional way to minimize the downtime as well as the cost of execution, while recording useful lessons learned at the end of the shutdown, for future similar jobs.

Why you should attend

Attending this course will help you master the following capabilities and skill:

1.    Organize the turnaround scope through internal coordination with various Company divisions (operations, projects, HSE and integrity…)

2.    Organize with external Parties on the scope and requirements such as Vendors, Contractors…

3.    Doing the macro planning to schedule material procurement, subcontractors mobilization, Vendor attendance

4.    Doing the detailed Micro Planning to define the optimum shutdown period.

5.    Develop manhour estimates and resource requirements to check Contractors proposals

6.    Develop the coordination procedures to ensure taskforce integrated efforts.

7.    Follow up the pre-shutdown preparations (material receiving, contractor mobilization,

Workshop Overview

The Workshop presents various planning and coordination efforts and procedures for various activities with the roles of various stakeholders from Company divisions and he final closeout report and lessons learned

Benefits of the Course

Through attending the course and workshop discussions, the attendees will:

Ø  Enhance their skills in Macro and Micro planning for the overall shutdown preparations and the detailed shutdown activities for the inspection and overhaul of equipment, execution of all shutdown-pending maintenance jobs.

Ø  Build the material requirements reservation lists and coordinate the procurement activities.

Ø  Build up manpower histograms for various trades and overall taskforce to evaluate Contractor offer

Ø  Learn how issue daily task lists to all the shutdown team members based on the overall shutdown plan and actual progress.

Ø  Issue daily progress report and coordinate the daily meeting presenting the way forward for the remaining period of the shutdown.

Ø  Issue the closeout report with finding and lessons learned.

All O&M and Projects Staff involved in plant operations and revamping, as needed, including:

Ø  Maintenance Managers

Ø  Maintenance supervisors

Ø  Maintenance planning Engineers

Ø  Inspection and Integrity engineers

Ø  Project engineers and supervisor.

Ø  Engineers, construction managers and commissioning managers

Ø  HSE engineers.

Diverse toolkits to:

1.    Develop and update macro and micro shutdown plans

2.    Material reservation lists

3.    Manpower histograms and lists.

4.    Contractor preparations and dedicated areas and facilities

Module 1 : Overview of Cost/Schedule QRA

1. Scope Definition; Plant items to be covered:
1. Stationary equipment (vessels, heaters,  exchanger..
2. (Endorsed periods (Regulatory, Company Strategy)
3.  )Rotating Machinery (CB or Company Strategy)
4. Shutdown and Safety systems (Regulatory).
5. Electrical Switchgear, MOV’s..
6. Critical online controls valves and shutdown valves.
7. Critical valves and piping lines..
8. Opportunistic repair jobs, pendning from prev. shutdowns.
9. Revamps, expansions, debottlenecks.

2. Scope Definition; Tools and Input Data

1.    RBI workshop to define top critical static/piping items.

2.    Equipment History

3.    5-year rolling plan for large turbo-machinery

4.    Condition Monitoring results

5.    Equipment Performance Records (seals, process parameters…)

6.    Statutory requirement (fired equipment, PSV’s…

7.    Opportunistic jobs (leaking v/vs…)

3. Manpower requirements and outsource arrangements
1. Detailed activity level duration and resource assignment.
2. Overall integration by category, by area.
3. Peak shaving policy.
4. Contractual stipulations on outsourcing
5. Logistics and site facilities.
6. Maintenance scheme during shutdown period; minimum.
7. Quality of outside labor
8. Site facilities and productivity issues.
9. Overnight shifts

10. Fallback plans in case of

4. Material identification, in-house check and procurement.
1. Material listing for various groups.
2. Stock availability and cross checks.
3. Material identification, in-house check and procurement.
4. Material Reservations
5. Lead times and market sourcing; a critical drivers
6. Fallback alternative arrangements with sister companies, air freight….

5. Tools, Software and skilled resources

1.    Need project planning expertise with CPM hands-on

2.    Need Primavera for planning (see attachments)

3.    Need Montecarlo for schedule QRA.

4.    Need MS office for manpower, reporting, presentation

5.    Need  contractual support/expertise

6. Execution Administrative procedures

1.    Open up contingent equipment (heaters..)

2.    Optimize resource allocation

3.    Night shift and limitations on activities.

4.    Vendor support.

5.    Cross-descipline coordination (Safety, Inspection…)

6.    Daily meetings, coffee breaks…

7.    Daily  progress monitoring and Reporting

8.    Decision making in serious findings

9.    Close-out reports and lessons learned.

7. Execution Technical procedures

1.    Equipment O & M Manuals.

2.    Company Maintenance Manual and PM procedures.

3.    WP procedures

4.    Inspection techniques and cameras, video recording

5.    Need History data

6.    P&I D’s

7.    Best Practices and industry standards

8. Organization and Human resources

1.    Shutdown officer

2.    Discipline superintendents

3.    Area engineers

4.    Foremen and trades

5.    Indirect labor (scaffolding, rigging, welding…)

6.    Inspection, Condition Monitoring, HSE and Process Staff.

7.    Home office 24/7 support

8.    Logistics

9. Shutdown Checklist
1. Barricades for unauthorized access
2. Permits for new buildings or modifications as needed
3. Contractor Insurance certificates
4. Dust control
5. Emergency shower and eye wash
6. Flag persons or traffic control
7. Solid and liquid waste handling
8. Noise control
9. Damage repair to plant assets (Contractual provisions)
10. Repair of pavement
11. Scaffolding control

10. Management decision on timing and timeframe.
11. Budget preparation
12. Vendor arrangements.
13. Shutdown Risk Management.
14. Wrapup and Top Ten Takeaways

BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.

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