Managing Shutdown and Trnarounds

 2.  Course Title

Managing Shutdowns and Turnarounds. 

4.  Course Duration

The is a 5 day course

5.  Number of Participants

A maximum of 10 participants can be accepted for this course

6.  Participant Profile (Who should attend)

Course Description: This course is for those supervisors, technicians and maintenance managers/superintendents involved in the management and operation of plant shutdowns. Turnaround management is very similar to project management though it has several very unique features.

There are two types of work on a turnaround, routine and unexpected. If the routine is under control there will be time to deal with the unexpected, but if the routine becomes unexpected the unexpected may become catastrophic. This course deals with these topics.

Audience Production supervisors, maintenance managers, supervisors and technicians, will be best prepared to gain from this course.

The delegate attending this Programme is designed for engineers and technicians with a minimum of 10 years experience.  Each candidate should have a good command of general English in order to gain maximum benefit from the course.

7.  Course Venue

The programme will be conducted at the client's premises

 
8.  Reports

Individual reports will be prepared for each delegatet for each module and will be forwarded to the concerned company and will include:

- Initial Assessment
- Detailed Assessment
- Expected Achievement
- Final Evaluation

9.  Programme Topics Covered

Detailed course content is given in the Course Outline, Section 10. However, the main topics covered are:
• Turnaround overview, context and strategy
• Planning the turnaround
• Validating a scope of work
• Contractor packages
• Planning the turnaround
• Turnaround organisation
• Site logistics
• The cost profile
• The safety plan
• The quality plan
• The communications package
• Executing the turnaround
• Terminating the turnaround

The classroom training is enhanced by the use of role-play, personal computer systems (CBT) where available and related exercises. 

In order to achieve the above, the programme is divided up into 3 modules comprising the following:

10.  COURSE OUTLINE

Turnaround overview, context and strategy

 Reliability, the fundamental driver
 Cost of the event
 Hazard to plant reliability
 Potential safety hazard
 Strategy
 Policy team concept
 Turnaround philosophy
 Maintenance scope pf work
 The engineering perspective
 Integrating all those concerned with the turnaround
 The phases of a turnaround
o Initiation
o Preparation
o Execution
o Termination

Planning the Turnaround

• The policy team and its purpose
• Provision of funds for the turnaround
• Balancing the constraints of the turnaround
• Setting the objectives
• Making a policy to meet the objectives
• Monitoring progress against the objectives
• Modification of objectives or policy
• Preparing the turnaround team
• Managers, engineers and other staff

Validating the scope of work

• Overcomplicated work requests
• Redundant work
• Desperation work
• “Blackmail” work
• The work list meeting
• Purpose of the meeting
• Participants in the meeting
• The scope of work elements
• Task and inspection review meetings
• Project work review meeting
• Vendor’s representatives
• Services, utilities and facilities

Contractor Packages

• Using contractors, the upside
• Using contractors the downside
• Contractor work packages
• Types of contract
 
Planning the Turnaround

• The major tasks
• Minor tasks
• Bulk work
• Shutdown start-up logic
• The shutdown network
• Start-up network
• The critical path program
• Optimizing the turnaround plan

The Turnaround Organisation

• Organisational combinations (Who will organise the turnaround? Who will do the
• Work?)
• How many people should be used?
• The hierarchical structure of a turnaround organisation
• The blend of the team?

Site Logistics

• The site logistics team
• The elements of site logistics
• The plot plan
• Preparation and issuing of the plot plan

The Cost Profile

• Why do we estimate a cost profile?
• The proposed cost estimate
• The approved turnaround budget
• Case study and its errors

The Safety Plan

• What is a hazard?
• The safety chain (Whose fault is it?)
• The safety communications network
• The safe working routine
• The hot-spot inspection
• Task hazard assessments
• The safety team
• Safety inspections
• The daily safety inspection
• The spot check
• Investigating accidents
• Why investigate?
• Case study

The Quality Plan

• Policy team issues
• ISO 9002
• Basic quality requirements
• Hold points
• Joints
• Case study

The Communications Package

• Issues and consequences
• Communication
• Situation briefing
• Timing
• The major task briefing
• Other briefings
 

 
Executing the Turnaround

• The event
• The routine
• The unexpected
• Shutting the plant down
• The turnaround manager’s routine
• Night shift progress
• Control of work
• Critical path job (CPJ)
• Expenditure
• Safety
• Site logistics, workshops and safety
• Permits to work
• Quality
• Co-ordination and control
• The daily turnaround program
• The unexpected
• Starting up the plant

Terminating the Turnaround

• Demobilising the site
• Final inspection and handover
• The “post mortem” debrief
• The final turnaround report

 
12.  Commercial Terms

The cost of the 5 day Shutdown and Turnaround course is available upon requesty.