Advanced Shutdown & Turnaround

24 Training Hours

​

Introduction

​

Owners of industrialized plants, manufacturing facilities, and commercial entities recognize that at some point their assets and equipment will require some form of maintenance. While several of the assets can be maintained during operational periods, major maintenance and capital improvements will require a process outage. This outage is commonly referred to as a “Plant Shutdown”. The management of this plant shutdown is referred to as the “Plant and/or Site Turnaround” 

Maintenance best practices suggest these shutdowns and turnarounds are a continuous process from one scheduled major outage to the next. This tactic/strategy supports the continuous planning and scheduling improvements that are critical to any shutdown and turnaround.  

Shutdowns for scheduled major maintenance and capital improvements are normally complex, and, as the complexity increases, they can become more costly and difficult to execute and manage. They are extremely expensive and time consuming due to the combination of loss of production and the expenses of the turnaround itself. On the positive side, which may not be recognized by senior management, assets are serviced to an acceptable operating standard and contribute to the plant's reliability, maintainability, and operational utilization. This process reduces the risk of unscheduled outages and/or catastrophic failures.  

A scheduled major plant or site shutdown is normally of short duration and high intensity, with considerable dollars being spent. Plant or site shutdowns are scheduled into the plant’s yield calculations and will therefore have a significant impact on the bottom line profits.

 

This workshop will provide you with comprehensive, interactive training to help you fully understand and apply concepts learned. 

 

Objectives

Better understand: 

 

• The standard shutdown steps taken by industrial companies to plan, schedule and control a shutdown or turnaround.

• Learn how to better integrate a service company's work planning with the planning of industrial asset operators.

• How to better identify, manage, and control the major shutdown variables, constraints, and risks during the implementation phase.

• How to build a stronger working partnership with the customer's Planning department by being better able to constructively contribute to the client's shutdown planning process and information.

• How industrial operators typically develop and control the scope of a shutdown.

• How industrial operators apply critical path and a flowchart or Gantt chart to trace out shutdown activities. For example, you will be able to define project-critical milestones, predecessor, and successor relationships.

• How to proactively detect schedule delays and stay on schedule and on budget.

 

Methodology

 

This course was developed using over 30 years of experience of world class best practices. The focus is on value adding activities and understanding shutdowns and turnarounds and their impact on the maintenance efficiency of critical physical assets as well as the budgetary impact. 

 

The exchange of instructor and students’ experiences, case studies and practical exercise complements positively the lecture.

 

Benefits

• Maintenance planning and scheduling prioritizes and organizes work in a highly efficient executable manner. 

• Effective utilization of planners, supervisors and craftspeople. 

• Lower costs due to efficient use of maintenance labor hours.

• Value adding management of information, risk and time. 

• Increased Asset Availability.

• Decreased unit cost of production.

• Sustainable increased profit margin.

• ​

Who should attend?

For experienced maintenance and engineering personnel interested in an advanced course which overviews operations training, accurate maintenance estimating, scheduling, and best practice maintenance planning.

​

This workshop will provide students with interactive training including practical and industry specific case studies.

 

• Shutdown Managers

• Maintenance Planners

• Maintenance Schedulers

• Maintenance Managers

• Maintenance Superintendents

• Maintenance Engineers

• Reliability Engineers

 

Key Topics

• Shutdown Goals

• Understanding Shutdown Macro-Management

• Key Shutdown/Major Maintenance Job Management Phases

• Shutdown Critical Path Principles

• Concepts & Principles

• Key Success Factors

• Elements of Shutdown Management

• Implementing and Controlling the Plan

 

What a Student Can Expect to Learn

• Shutdown process

• Shutdown life cycle

• Shutdown measures

• Elements of shutdown management

• Shutdown plan control points

• Shutdown process checklist

 

 

​