Physical plant representative in consultation with director of facilities planning and facilities planning engineering section, schedule a logistics meeting, as early as three 3 weeks and no later than ten 10 calendar days prior to, proposed shutdown. Our promise for this program is that you will have a new and deeper understanding of how to effectively manage large maintenance jobs such as power plant outages and refinery refits. Planning it is no surprise that having a detailed, wellthought out plan is the first step to a successful plant turnaround. Pmaops521c plan plant shutdown modification history not applicable. Appropriate expertise can be gained especially for the production phaseout a repeated procedure, which is the operative implementation of every plant shutdown, but also takes place during. Major maintenance shutdowns can be stressful for both maintenance and operations personnel, but with careful planning and attention to details, they can also. Effective plant shutdown, turnaround, and outage sto. Building the plant maintenance shutdown plan maintenance sme. A case study article pdf available in journal of quality in maintenance engineering 142. An effective method is developed for shut down management of coal handling plant of thermal power stations. Ensure all required ppe is available on site and inspected or will be brought on site by vendors. In contrast, the typical shutdown lasts from one to three weeks and the deliverable is a properly running plant that is gmpcompliant.
Turnaroundshutdown optimization plan for the 5 phases of a plant maintenance shutdown by david neikirk, senior project manager a turnaround ta by definition is a planned, periodic event where one or more processingproduction units are temporarily removed from service. A successful plant shutdown starts with a safe workforce. There are a lot of elements to deal with and expertise that you may not possess on your own. The single best thing you can do for a successful plant shutdown is to give yourself enough time to plan the outage effectively. Manage siteplant access for resources, vehicles, equipment, and tools. Big rock point plant, post shutdown decommissioning. When a turnaroundshutdown is declared the planning group should develop a full list of the existing work as a basis for the turnaroundshutdown work list. Day of the shutdown personincharge conduct a prejob walk down of the mop and rehearsal meeting with vendors.
Whether youve just started planning for a power plant outage, are in the middle of outage planning, or are dealing with an unplanned plant shutdown or turnaround, ge has the expertise and services to help. It is estimated that shutting down a plant for a few weeks can cost the plants entire maintenance budget for a year. It is imperative to get management support for the plant turnaround or. Shutdown communications email is a problem reply all mass distribution lists not everyone has email access noticeboards not very effective toolbox talks are very effective meetings work well large mass meetings do not work well signs work well for operators flashing signs work extremely well jury is still out on intranet your audience is not. Turnarounds are unique maintenance projects with a high probability of scope change, time delay, and cost overrun. Once the cutoff date has passed and the complete scope of the shutdown is known, the final work list can be compiled and reconciled against the available budget. The case study highlights that collaborative planning and execution of tam are. How to enhance the companys turnaround management capabilities, and to ensure a team approach in the planning and execution of plant shutdowns and turnarounds to provide a comprehensive understanding of effective shut down management techniques and implementation. This competency requires the application of a detailed plant knowledge to the task of developing a detailed shutdown plan. Good planning is the key to a successful plant shutdown. Strategies to optimize shutdowns, turnarounds and outages. This competency is not actually about the shutting down of the plant itself see pmaops411b manage plant shutdown and restart, nor.
As with nonshutdown maintenance, the single biggest factor that impacts shutdown management is the operating schedule. This is the opportune time to replace wornout or broken process materials and equipment at their useful endoflife. Managing a successful temporary plant shutdown and return to service the temporary shutdown of a manufacturing plant for improvements in equipment and processes must be made with the utmost planning and coordination to achieve the desired aims in. Without careful planning and risk management, delays can cause the cost of lost production to far exceed the planned maintenance costs of a shutdown.
Turnaround is a planned shutdown of any plant where a large number of activities, in terms of various of discipline have to be executed in a specified predefined duration. The revised guide incorporates lessons learned following shutdown and restart of nuclear power plants due to earthquake ground motion and post. Planning your plant shutdown should definitely not be a solo effort. Planning for shutdowns and outages life cycle engineering. Postshutdown activities and completion of the shutdown report phase one. Turnaround, shutdown, outage or revision there are many names for the complex event in which an entire process unit in oil or gas production is taken offstream for renewal. During a sulphuric acid plant shutdown, a long list of work needs to be completed in limited space and as quickly as possible. The costs for a plant shutdown are calculated in two areas. The best way to proceed is to delegate brainstorming and workgroup sessions involving other department stakeholders to other. It is important to have a specialized team dedicated to your plant shutdown, in both the planning and execution phases.
Manage indirect hire, contractor, subcontractor, and service personnel at the siteplant. Detailed planning can strain a team already busy with operating, maintaining and upgrading the plant. The 5 phases of an effective plant maintenance shutdown. Monitoring plant shutdown and turnaround performance needs a mix of lagging and leading measures and indicators. An effective plant shutdown should result in reduced unplanned downtime, reduced overtime, and greater operational efficiencies. The following are some of the best safety practices for a successful plant shutdown. Sap project systems plant maintenance utilization for plant wide shutdown. Planning is needed to react to unplanned events, stay on top of. A documented procedure, communication, and welltrained team are key.
Shutdown and turnaround management explores various types of shutdowns, presents recommendations for better management, and offers feasible solutions to help reduce overheads. Planning for shutdowns, turnarounds and outages training. Thats because some maintenance tasks cannot be performed unless the entire unit is taken out of service. Planproposal by project management professional turnarounds. In a traditional project, the completion of the project delivers a product or service and lasts months, if not years. A small investment in kt is minimal compared to the total costs of your shutdown or the risks of a poorly. Attempt to anticipate unexpected events and identify and minimize all possible hazards. After attending this 3day course, you will save time and money on your next shutdown. The challenges of shutdown management in the petrochemical. A new methodology for improving tam scheduling of oil and.
Interplant or facility coordination capital or investment planning individual plant or unit mechanical performance regulatory and legal requirements turnaround timing to ens ure minimal lost profit opportunities value of downtime evaluation of which plants or units to shutdown at the same time. The guide proposes guidance acceptable to the nrc staff regarding preearthquake planning actions, actions to determine the need to shutdown a nuclear power plant and the shortterm and longterm processes, inspections and tests that are acceptable to demonstrate that a nuclear power plant is safe for restarting after a shutdown due to an. Plan for the 5 phases of a plant maintenance shutdown. Safety practices for a successful plant shutdown craftforce. Turnaround maintenance management in a processing industry.
The critical path method cpm or sometimes a gantt charts is used for planning shut down. Plant shutdown turnaround management monitoring kpi key. Careful safety planning of any turnaround is critical. Thanksgiving and the end of the year is shutdown time for many companies, so its important to get on the books early. Order any needed equipment well in advance of your shutdown period. A shutdown is a maintenance event where an entire process plant or unit is taken out of service to perform specific maintenance tasks. At the meeting, nature of shutdown and proposed date and time of shutdown will be. Safety tips for managing a plant shutdown or turnaround. Major maintenance shutdowns can be stressful for both maintenance and operations personnel, but with careful planning and attention to details, they can also be very rewarding. In june of 2015, nestes porvoo refinery in finland completed the largest turnaround in its history. Clientfacility was already an established user of sap pm but was looking for a more effective way to plan and schedule work for an extremely aggressive 14 day total plant shutdown.
Shutdown planning and scheduling requires 100% focus, and a dedicated team. A framework for the successful implementation of turnaround. Managing a successful temporary plant shutdown and return. The process of project management is generally applied to a maintenance shutdown in coal handling plant of thermal power stations. The shutdown manager evaluates the actions to be made, builds a planning team, involving the technicians of the various plant functions. The brehob team put together this plant shutdown checklist based on our experience helping our customers plan and implement turnarounds.
Standard shutdown management kpis tend to be historic measures of turnaround goal achievement, but it is also necessary to have predictive indicators of shutdown planning performance. Process improvement for power plant turnaround planning and. Because turnaround management is the largest maintenance activity, plant. Accountability and specific responsibility for key shutdown roles. Ensure your safety plan details all shutdown and turnaround activities to identify. The cost of ceasing operations for an extended period of time. Preshutdown activities planning and scheduling confirm who must do what. The plan should include clear items for when the shutdown will begin and end, what equipment will be removed, what equipment will be repaired, what equipment will be replaced, what maintenance and inspections will be. Unit descriptor unit descriptor this competency covers the planning of work to be done in a plant shutdown or outage, eg maintenance or inspection shutdown of a plant. Take a look below, download a printable copy to reference later, and be sure to contact us to get on the schedule for shutdown service. Shutdown coordinatorsplanners shutdown leader plant owner your shutdown management team.
It has been shown that success is concerned primarily with the planning process before the shutdown begins. Five distinct phases of a plant shutdown are scoping, planning, scheduling, execution, and wrap up. Our power plant outage services team has broad experience handling both planned and unplanned outages and can service crossfleetother. Pdf turnaround maintenance management in a processing. But it is observed that existing method is not sufficient and foolproof for such type of work. Key principles for successful shutdown maintenance planning. Turnaroundshutdown optimization plan for the 5 phases of. Attempting to share resources between regular maintenance planning and shutdown planning is a big mistake. Federal register preearthquake planning, shutdown, and.
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