The course will cover the emerging industry trends, turnaround benchmarking and the challenges faced by plant executives to consistently achieve pacesetter results on plant shutdowns and turnarounds. We will teach you how to fairly balance your business, marketing and financial goals with your plant needs for mechanical integrity and operational reliability. We will show you how to focus on risk areas, early work scope definition, high-performance initiatives, the assignment of qualified staff and the best practice contracting strategy. Upon the completion of this course, you will have good knowledge to perform World-Class turnarounds.
By the end of the course, participants will be able to:
- Apply systematic techniques in the shutdown, turnaround and troubleshooting of process plants
- Implement the special needs of time constrained projects (24/7)
- Identify the work to be accomplished for the shutdown project
- Plan to meet deadlines & complete turnaround projects on time within budget
- Apply shutdown best practices
- Plan, lead, organize, control and co-ordinate shutdown type projects
- Schedule the work effectively
- Manage resources effectively
- Implement feedback systems
- Identify risks and manage these effectively
- Reporting and documenting the shutdown activity
Who should attend
This course is intended for those involved directly or indirectly in the plant shutdown and turnaround operations. This includes maintenance and project staff such as managers, engineers, planners, supervisors and other technical people.
Course Introduction and Fundamentals of Shutdowns Course Expectations ● Shutdowns and Project Management – Unique Features
Types of plant shutdown, Annual shutdowns (preventive/predictive), Urgent shutdowns (breakdowns) etc.
Structure of the Shutdown Compiling and Defining the Scope of Work and Budget ● Operations & Maintenance Inputs ● Kickoff Meeting Agenda – Structured Group Interviews ● Identifying Pre-Shutdown and Start-up Work ● Validating the Work
Macro vision of the Functions in the plant shutdown Planning
Structure of the Shutdown Planning Lead Time – Planning Phase is Actually a Project on its own ● Project Work Hours and Shifts ● Project Charter and Scope Control ● Risks Assessment ● Quality Control Requirements ● Checklists and Action Item Lists ●
Planning Processes and their Application. The Planning Tasks Cycle ● Work Breakdown Structure, Organization Breakdown Structure ● Activity Lists ● Activity Information Determination- Duration, Resources, Costs ● Dealing with Uncertainty in Job Estimates ● Class Tasks
Base-line Plan, with Budget Approval, Work Milestones and Constraints ● Network and Dependencies ● Gantt Charts – Master and Daily Schedules ● Resource Planning ● Cash Requirement and Flow Planning ● Confirming the Shutdown Budget
Organizing and People Management Organizing the Shutdown Project Team–Selecting the Manager ● Organizing Contracts and Procurement ● Tracking Shutdown Materials ● Coordinating Support Equipment.
Turnaround overview: context and strategy, initiating the Turnaround, Validating the work scope, Shutdown Contract Management, Scope Development Execution and Closure:
- Current methods verses best practices, • Specific turnaround goals and objectives
Understanding— turnaround priorities, performance enumeration scales that align
Contractor packages, Planning the Turnaround, • Aligning turnaround projects and modifications Barriers and keys for the success of a plant shutdown, Class Tasks
Work Documentation Needed and its Organization ● Organizing the Store and Procurement Processes (Before and During) ● Organizing Progress Feedback ● Organizing Start-up and Handover Work Packages
Execution and Feedback Methods and Documentation ● Meetings ● Materials Management ● Accounting – Time and Materials Systems for Feedback ● Timeous Staging ● Quality, Safety and Activity Completion ● Time and Materials Systems for Feedback ● Timeous Staging ● Tracking Shutdown Materials ● Coordinating Support Equipment ● Quality, Safety and Activity Completion ●
Logistics , Cost control , The safety plan -Shutdown Safety, Risk in Shutdown, The quality plan , The communications package , Executing the Turnaround , Pre-shutdown Job, Class Tasks
Control of Shutdown – Review of Day 3 Work Methods of Control ● Time Control from Feedback ● Money Control from Feedback
Scope Change and Impact Control ● Project Acceleration ● Class Tasks
Contractor Controls and Safety Control, Starting up and Handover Schedules and Checklists ● Completion Sign off Certificates ● Payment Certificates (as Applicable) ● Accounting Reports ● Payment of Contractors
Equipment Inspections and operations Shutdown Control, Joint Integrity, Commissioning, Terminating the Turnaround
Shutdown Groups Workshop Briefing and Group Selection ● Shutdown Planning in Groups per Briefing, Shutdown Plan Presentation, Summary, Open Forum and Closing, Class Tasks
This interactive training course includes the following training methodologies as presented on the next column based on percentage of the total tuition hours:
Workshops & Work presentation
Case Studies & Practical Exercises
Videos, Sofware & General Discussion
The course instructor may modify the above training methodology before or during the course for technical reasons with no prior notice to participants.