A plant turnaround or planned shutdown for scheduled maintenance and modification of plant and process unit are the most expensive, complex and difficult to manage maintenance projects in oil, gas and petrochemical industry, typically accounting for about 25% of the maintenance expenditure. It is a scheduled period of non-production where day-to-day operations cease completely and focus shifts to plant modifications, maintenance-related activities, cleaning, inspection and repair. During this time, the plant’s employees and outside contractors, work around the clock to get everything ready for the plant or process unit to resume its regular production and operations.
Speed is critical when it comes to shutdowns because they are extremely expensive in terms of production lost, increased labor and equipment expenses. Turnarounds, therefore, can strongly affect a company’s bottom line. A turnaround that goes badly, lasts for too long, or exceeds its budget could result in the company unexpectedly incurring losses. On the other hand, a turnaround that is executed successfully and stays within its budget and timeline will make a huge contribution to the plant’s economic efficiency and safety.
This training will feature:
- Overview of typical turnaround management techniques
- Analysing, compiling and communicating the initial scope and estimates of a turnaround project
- Managing a turnaround project from planning and execution to handover stage using a case study
- Applying the appropriate shutdown planning and best practices to ensure shutdown duration can be reduced to avoid unnecessary work and making a proper schedule
- Developing an effective maintenance plan for shutdowns to ensure shutdown work quality gets improved with minimal chances of rework
- Using appropriate techniques to identify risks and manage them effectively
- Managing available resources (personnel, materials and equipment) for a turnaround project so that reduced cost is possible due to effective usage of resources
- Developing the turnaround management plan, resource plans, budget and work plans in order to achieve improved planning and communication
By the end of this training course, participants will be able to:
- Understand what entails in turnaround management
- Understand the complexities in developing the scope of work and estimates of a turnaround project
- Appreciate the complete metamorphosis of turnaround project –from Planning & Execution till Handover phase
- Understand the shutdown planning schedule and the best practices to mitigate rework
- Understand how to develop an effective maintenance plan for shutdowns
- Fully understand how risks are identified and how it is managed
- Understand the processes involved in developing the turnaround management plan, resources plan and budget for the turnaround works for both onshore and offshore
DAY 1
INTRODUCTION TO TURNAROUND WORKS FOR ONSHORE PLANTS AND OFFSHORE FACILITIES
- Introduction to the course
- Pre-course assessment test
- Identify and set the expectations of the course participants
- Learning objectives of the course
- Introduction to Shutdowns and Turnarounds
- Shutdown Planning Strategy
- Shutdown Governance and Key Milestones
- Shutdown/turnaround problems and issues
- Management planning
DAY 2
PREPARATION OF SHUTDOWN/TURNAROUND WORKS
- Shutdown/Turnaround Preparation for Maintenance
- Scope of Work Development and Optimisation
- Work Breakdown Structures
- Case Study work
- Organisation and Roles
DAY 3
PLANNING METHODS FOR SHUTDOWN/TURNAROUND WORKS
- Shutdowns/Turnaround Planning Techniques
- Developing Shutdown and Turnaround Plans
- Turnaround Planning Process
- The Critical Path Planning Method
- “Short Cut” Planning Methods
- Scheduling multiple projects
DAY 4
PROJECT CONTROL FOR SHUTDOWN/TURNAROUND WORKS
- Costs, Control and Contractors
- Budgets, Cost Estimating and Control
- Developing shutdown budgets
- Progress, cost control and productivity tracking
- Materials planning and control
- Contracting and Tendering Process
- Contractor Management
- Procurement and Materials Management
DAY 5
HSE / QAQC / EXECUTION OF SHUTDOWN/TURNAROUND PROJECTS
- Health, Safety, Environment Management
- Quality Management - QAQC
- Risk Management
- Integrating risk management into the shutdown plan
- Execution of Turnaround projects
- Post Turnaround activities
- Post-course assessment test
This training course is suitable to a wide range of professionals but will greatly benefit:
- Field Engineers
- Construction Supervisors
- Project Engineers
- Operations Engineers
- Workpack Engineers
- Structural Engineers
- Pipeline Discipline Engineers
- Maintenance Engineers
- Cost Estimating, Project Control and Planning Engineers
- Other Engineers and technicians in the maintenance field who need to update their current Oil and Gas industry experience and wanting to move to offshore Projects