Refineries extreme safety and continuous operation constriction requirements demand properly designed and executed shutdowns together with increase in efficiency with the use of latest technologies place massive importance on properly designed and executed shutdown and turnaround.
This Refinery Shutdown and Turnaround introduces the methodologies to plan execute major overhaul and upgrading in the most efficient and cost-effective way of the highly complex refinery structure.
This Refinery Shutdown and Turnaround training course emphasizes the optimization of the shutdown work structure, so assets remain reliable and efficient with minimization of the required shutdowns throughout the life cycle of the Refinery.
This training course will highlight:
- Use of API 571 for work identification for static equipment and other international codes for dynamic equipment
- Sizing work requirements using API 579
- Creation of the appropriate Work structures to avoid repletion and minimize personnel engagement
- Use Gantt charts to monitor execution and keep in time
- Use of CPM PERT techniques for scheduling
- Use failure mathematics to safeguard risk on planning activities
- Assess turnaround with the appropriate efficiency testing and indicators
By the end of this training course, participants will be able to:
- Understand the Failure mechanisms of Refinery applying API 571
- Size the necessary work for Assets life maximization using API 579
- Apply the correct type of turnaround for each asset
- Schedule work activities
- Control time, budget and scope during shutdown
- Assess performance of Turnaround
DAY 1
REFINERY SHUTDOWN TYPES & ASSET PAIRING
- Definitions of Shutdown, Turnaround
- Material failure and degradation in Refinery using API 579
- Refinery structure and units sensitivity to failure
- Failure rate mathematics the basis of Reliability center maintenance
- Shutdown and the life cycle of Refineries
DAY 2
SHUTDOWN & TURNAROUND PLANNING
- Refinery Work Order system (WO) input for Planning
- Size of work using API 579 and create Work Breakdown Structure (WBs)
- Creating the most appropriate organization structure to run the shutdown
- Spare parts and materials required for the shutdown
- Personnel internal or subcontractors required for shutdown
DAY 3
ORGANIZING THE SHUTDOWN TIME SEQUENCING
- Work sequencing optimization
- Material –personnel- contractors’ constraints
- Fitting the optimum number of shutdowns in the life cycle of Plants
- Utilization of timing techniques (CPM-PERT)
DAY 4
CONTROL OF SHUTDOWN TIME, COSTS & WORK QUALITY
- Gantt charts for keeping in time
- S- curve usage for budget monitoring
- Financial reserves for uncertainties
- ISO/API standards for work handover
DAY 5
SHUTDOWN PERFORMANCE ANALYSIS & TURNAROUND EFFICIENCY MEASUREMENT
- Asset Turnaround Performance Indicators
- Shutdown Workload Performance Indicators
- Shutdown Planning Performance Indicators
- Turnaround Effectiveness and cost Performance Indicators
- Shutdown and Turnaround data archiving and future recommendations
It is highly recommended that Refinery maintenance, reliability, engineering and technical support staff including leadership and management to attend this Maintenance Engineering training course. Also, including:
- Planners
- Supervisors
- Engineers
- Reliability Engineers
- Maintenance Team Leaders and Managers
- Operations Team Leaders and Managers