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Effective Plant Shutdown And Turnaround – Topics

TOPIC 1

OVERVIEW OF SHUTDOWNS AND TURNAROUND MANAGEMENT

  • Understanding the importance of managing shutdowns
  • Effectively
  • Looking at the basic approaches to shutdowns:
  • Turnkey
  • Loose control
  • Tight control
  • Outlining the differences between approaches
  • Providing you with the ingredients for successful shutdowns
  • Looking at management responsibility
  • Identifying the various phases of shutdowns
  • Identify the work
  • Planning the work
  • Scheduling the work
  • Executing the shutdown
  • Shutdown close – out

TOPIC 2

DIFFERENCES BETWEEN PROJECTS AND SHUTDOWNS

  • Organizing the shutdown
  • Understanding the role importance of the shutdown coordinator:
  • Personality traits
  • Roles and responsibilities
  • Shutdown organization
  • Options to the shutdown organization
  • Example : organization structure for a 24/7 shutdown

TOPIC 3

QUALITY PROCESSES

  • Quality control
  • Quality assurance
  • Quality management small projects
  • Quality management large projects

TOPIC 4

SAFETY PLAN

  • Shutdown coordinator
  • Engineers
  • Supervision
  • Workers

TOPIC 5

ISSUES TO BE ADDRESSED IN THE PLAN

  • The model of excellence for Turnarounds (MOE)
  • A frame work for excellence (Benchmarking against best practice)
  • The various uses of the MOE (a versatile tool for improvement)
  • The critical elements of the MOE (mapping out effectiveness)
  • The sub – elements of the model (handling the fine detail)

TOPIC 6

SHUTDOWN WORK IDENTIFICATION

  • Maintenance shutdown scope
  • Categories of work
  • Issue to consider
  • Defining and limiting scope
  • Pre-shutdown work
  • Sources of shutdown work
  • General shutdown checklist
  • Compiling identified work
  • Works order, purchase orders, permits, etc
  • Final work list
  • Parts, materials and equipment
  • Master materials list
  • Shutdown constraints – elapsed time, resources, funds
  • Prioritizing the work
  • Job input cut-off date
  • Assignment responsibilities

TOPIC 7

WORK SCOPE SUPPORT PLAN

  • List the eight required support plan systems
  • Develop the support plan work package
  • Describe the support plan systems
  • The critical of the support plan
  • Shutdown planning and Scheduling

TOPIC 8

PLANNING THE PLAN

  • Goals and objectives
  • Time
  • Cost
  • Quality
  • Safety
  • The ‘hot’ spot of projects
  • General conflicts

TOPIC 9

PLANNING THE WORK

  • Work planning flowchart
  • Convert tasks to work orders
  • Elapsed time and staffing
  • Work packages
  • Roles of operations
  • Precedence networks
  • What is programming
  • Activity sequencing
  • Creating the logic network
  • Plug dates

TOPIC 10

RESOURCE SCHEDULING

  • Adding activity duration
  • Further considerations e.g. weather
  • ACTIVITY PARAMETERS – MEANINGS AND CALCULATIONS
  • Early start
  • Early finish
  • Late start
  • Late finish
  • Total float (slack)
  • Free float (slack)

TOPIC 11

THE CRITICAL PATH

  • What is it and how is it used?
  • The sub – critical path
  • Negative floats (slack)
  • Bar Charts
  • How derived
  • Example
  • Resource Smoothing
  • Resource budgeting
  • Types of resources
  • Resource Leveling
  • Example of Resource Leveling
  • Setting key events and milestones
  • Shortening the critical path
  • Crashing activities and shutdown
  • Time/cost considerations for critical path shortening
  • Schedule control

TOPIC 12

THE USE OF CONTRACTORS

  • When are contractors
  • The advantages and disadvantages of contractors
  • Selection of contractors
  • Creating contractor work packages
  • Types of contracts
  • Fixed price
  • Cost reimbursement
  • Time and material
  • Unit price

TOPIC 13

CONTRACT STATEMENT OF WORK

  • The contracting/purchasing process
  • Planning the contract
  • Evaluation criteria
  • Requesting contractor responses
  • Selecting contractors
  • Administering the contract
  • Closing the contract

TOPIC 14

NEGOTIATIONS

  • What is negotiations
  • The negotiation process
  • Negotiation tactics

TOPIC 15

CONTRACT MANAGEMENT

  • Before the event
  • During the event
  • After the event

TOPIC 16

SHUTDOWN BUDGETING AND CONTROL

  • What is cost and cost management?
  • Cost management processes
  • Cost estimating
  • Cost budgeting
  • Cost control
  • Cost management plan
  • Creating a shutdown budget Topic 20
  • Included in the budget
  • Excluded from the budget
  • Project cost control
  • Project costs
  • The ‘S’ curve
  • Earned value management (EVM)

TOPIC 17

THE CONTRACTOR MANAGEMENT PLAN

  • Classification of contractors
  • Managing the bid stage and award
  • Effective mobilization
  • Efficient demobilization
  • Contractor Momentum
  • Establishing critical path momentum
  • How to motivate the contractor
  • Understanding the ‘S’ curve

TOPIC 18

MANAGING LOGISTICS IN SHUTDOWNS

  • Logistics functions during shutdown
  • Duties of the logistics team
  • Duties of the logistics coordinator
  • Storeroom management -24/7 shutdowns
  • Management of long lead time items
  • The process
  • Effect on milestones
  • Expediting

TOPIC 19

RISK MANAGEMENT

  • Component of risk management
  • Identification
  • Quantification
  • Response
  • Response control
  • Secondary risks
  • Retained risks
  • Contingency plans
  • Unplanned events
  • Unexpected gains
  • The contingency plan

TOPIC 20

SHUTDOWN EXECUTION

  • Managing The Work Quality
  • Shutdown Master Schedule
  • Daily work schedule
  • Emergent work
  • Safety during the execution
  • Job status update
  • Controlling the shutdown
  • Role of the shutdown coordinator in 24/7 shutdowns
  • Report shutdown status
  • Why shutdowns failure

TOPIC 21

SHUTDOWN CLOSE – OUT

  • Shutdown review meeting
  • Project file
  • Final report
  • Shutdown post mortem
  • Aspects to consider
  • Review and analyze
  • Action plan
  • Next shutdown

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