Engineering and Maintenance
Plant Annual Shutdowns and Turnarounds

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Plant Annual Shutdowns and Turnarounds Course
Introduction:
Course Objectives:
- The program’s principal objectives are:
- The management of overall shutdown phases.
- How to develop the scope of work and Planning Techniques.
- Case Study of oil /gas shutdown plan.
- How to prepare work package for each individual job.
- Effective workforce management and organization.
- Shutdown production operation.
- Costs & Contractors optimum control.
- Management the execution in the face of reality.
- HSE Management System and Manage risks.
- Measurement and reporting the progress
- Reporting the completion /close up
- Preparation for startup
Who Should Attend?
Maintenance Managers, Engineers, Supervisors and qualified senior technicians. Planning Managers, Engineers, planners and qualified assistance planners. Production Managers, Engineers, Supervisors and qualified senior operators
Course Outlines:
Definitions
- Basics of Shutdowns, Turnarounds, and Outages
- Different between Shutdown, Turnarounds and outages
- Different between Project and Turnaround
- Turnaround life time & objectives
- Turnaround/Shutdown Communications
- Turnaround/Shutdown Phases
- How to justify the Turnaround / Shutdown
- Timelines and audits
- Turnaround/Shutdown Organization
- Master Schedule for Phase 1 Initiation
- Shutdown/Turnaround Preparation and Planning
- Typical Story of maintenance planning (Case Study)
- Definitions and Reasons for a Planning
- CMMS as a tool
- Scope of Work: How to Find and Pick the Jobs
- Work Validation and preparation for planning
- Individual Job Planning
- Case Study for scope of work preparation
Planning Techniques
- History of Project Management
- Key concepts for all PM techniques
- Critical Path Method (CPM)
- Resources
- PERT and newer methods
- PM (Project Management) Software
- Master Schedule for Phase 2 Planning
- Case Study - Oil/Gas Shutdown Plan using MS-Project Software
- Shutdown/Turnaround production operation
- Production Shutdown /Turnaround Planning
- Shutdown/Turnaround operation and safety procedures
- Production Shut-down Preparation Main Considerations
- Normal Process Plant Shut-down
- Normal Utility Plant Shut-down
- Major Shut-down of Process Equipment and Modules
- General Considerations for Process Plant Shut-down
- Equipment or section isolation
- Type of Isolations
- Isolation reporting
- Mechanical Isolation Detailed Sheet
- Major Isolations
- Electrical Isolations
- Safety Lock-off Systems
- Case Study
- Particular consideration when pressurizing and depressurizing vessels
- Interface between production & maintenance
Cost & Contractors Control
- Contractors:
- Contracts & Outsourcing Strategy & Contractor Management
- How to integrate external organizations
- Budgets & Costs control
- Logistics
- Spare parts Management
- Organization for the parts, materials and supplies
- HSE Management System
- Understand Hazard & Risk
- Manage Risk
- Assessment control & monitoring (JSEA & PTW)
- Plant operating procedures
- Human factors
- Commit to Process Safety Culture
- Training and performance assurance (CAMS)
- Management of change