Course Overview

Shutdowns for scheduled major maintenance work are the most expensive and time consuming of maintenance projects because of the loss of production and the expense of the turnaround itself. They can be complex; and as the complexity increases, they become more costly, risky, and difficult to manage.
This course will explain the efficient shutdown & turnaround management process step by step with deep insights and important guidelines/best practices.
This course introduces the concepts associated with the successful planning and execution of major plant shutdown. At the end of the course, the participants will be able to understand the best practices involved in managing plant shutdown, and therefore will be able to enhance or upgrade organization shutdown management capabilities.
The course will also identify the ingredients which need to be managed effectively and optimised to achieve this result. A framework for efficient, effective, and timely action will be given.
The course will provide participants with competence in the use of modern, well proven approaches, tools, and techniques to achieve this desirable end result.

Course Objectives

To highlight the importance of the shutdown, explain its characteristics, phases, and business process
Provide a comprehensive understanding of effective turnaround management process, techniques, and implementation
To shed the lights on the shutdown risks and explain how to control, manage, and mitigate
To explain the mission, decision, inputs, deliverables, gates, and controls in each phase of the shutdown
To explain in detail how to: scope the shutdown work, budget it (including cost estimation and control), plan/schedule it (through planning techniques including critical path method), prepare the required resources and equipment, schedule it and execute it safely and efficiently
To explain in detail how to maximize the role of the Computerized Maintenance Management System (CMMS)/Asset Management System (AMS) in shutdown management
To explain how to manage and maximize the utilization of the shutdown resources efficiently, monitor, report, measure the performance and control the shutdown activities
To explain how to make the shutdowns a continuous learning and improvement process
To enhance the company’s shutdown management capabilities, and to ensure efficient approach in the planning and execution of plant shutdowns and turnarounds
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
Upon completion of this course, participants will have gained a solid understanding of the key elements of successful shutdown management.

Who Should Attend The Course

This is a comprehensive core skills course for professionals dealing with all significant aspects of the management of shutdowns and turnarounds.
This includes Maintenance Engineers, Maintenance Superintendents, Supervisors and Foremen, Maintenance Planning Engineers, Maintenance Planners/Schedulers, Shutdown Managers and coordinators, Project Engineers, Operation Engineers, Integrity Engineers, Technical Personnel, and Operations staff involved in Shutdowns.

Course Outline:

DAY-1

Introduction
Shutdown Planning
Long Term Shutdown Strategy
Questions to be posed by Senior Management
Shutdown Cycles
Steering group concept
The Steering Group/Committee
The Purposes of the Steering Group
Shutdown Phases/Process
1. Initial Phase (Assess Phase)
Mission
Decision
Inputs
Deliverables
Conceptual Development Activities
Assess– gate milestones
Controls during Initial Phase
Shutdown Organization

DAY-2

2. Planning and Preparation Phase (Select Stage)
Mission
Decision
Inputs
Deliverables
Select – Gate Milestones
Shutdown Execution Strategy
Detailed Planning & Scheduling- Activities
Examples of Shutdown Formal Meetings
Documentation
Scope Development – Sources
Planning the Work Scope
Work Scope Elements
Planning Step One: Developing the Shutdown
Work List
Planning Step Two: Identify Task Relationships
Optimizing the Turnaround plan
Contingency planning
Defining emergent work
Finalizing the plan
Commissioning
Definitions
Typical Project Phases (European Terminology)
Starting up the Plant (Commissioning)
Commissioning
Commissioning Phases

DAY-3

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:
Develop Resource Plan
Planning Step Seven: Develop Procurement Plan
The safety plan
Planning Step Eight: Develop Quality Plan
The quality plan
The communications package
Critical Preparation Work
Contracting

DAY-4

3. Pre- Shutdown (Define Phase)
Mission
Decision
Inputs
Deliverables
Safety Training
Activities During the Week Prior to Turnaround
Pre-shutdown Action Plan (Typical)
4. Shutdown Execution Phase
Mission
Decision
Inputs
Deliverables
Shutdown execution Phase
Types of Work in Shutdown
Shutting the Plant Down
Shutdown Execution
Some Typical Operations Carried out During a Refinery Turnaround

DAY-5

5. Closing out Phase (Operate Phase)
Terminating the Turnaround
Mission
Decision
Inputs
Deliverables
Closing out Phase Main Work
Administrative Closure
Documenting the Shutdown
Inspection Report
Inspection Certificates
Safety/Environmental Performance and
Procedures
Contractor Performance
Schedule Compliance
Costs
Final Report on the Shutdown
Key Performance Indicators for Plant Shutdown
Turnaround Leading Indicators
KPIs Used to Measure Shutdown Performance
Targets (Examples)
KPIs Used to Measure Shutdown HSE KPIs
(Example)
Examples of TA KPI Interpretation
Conclusion
Project Management Principles and Practices as Planning and Scheduling Main Tool
Project Management Principles and Practices
Bar Charting Plans and Activities
Program Evaluation and Review Technique
(PERT)
Critical Path Method (CPM)
Milestones
Tracking Plans and Progress with Tracking Bar Chart and Critical Path
Progress Report (S-Curve)
Why Use an S-curve?

Training Methodology

The program will be highly interactive, with opportunities to advance opinions and ideas. Participation is encouraged in a supportive environment. To ensure the concepts introduced during the program are understood, they will be reinforced through a mix of learning methods, including lecture style presentation, open discussion, case studies, exercises, videos, and group work.

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