Course Overview

Planning and managing shutdowns, turnarounds and outages in the process plant environment is a complex and demanding function. They are high-risk events due to the high level of activity taking place in a compressed time frame and added to that the uncertainty associated with the work scope and all the other uncontrollable factors. It is, therefore, no surprise that more and more organisations are reviewing their shutdown and turnaround practices to improve.

Shutdown/turnaround costs comprise up to 30% or more of annual maintenance budgets, and a delay in a start-up can cause a loss of operating profit that exceeds the cost of the shutdown/turnaround. Planning and executing a turnaround event require many people to be diverted and external resources to be contracted. They can be costly in terms of lost production, so a carefully designed plan can reduce costs.

Minimizing the duration of the outage can have a major impact on reducing the cost of lost production. Augmentation of resources available to handle the planning and scheduling and then the execution and assisting in the start-up of the facilities will minimize the out-of-service time.

Course ObjectivesBy the end of this training participants will be able to:

• Enhance the company’s turnaround management capabilities
• Apply a team approach in the planning and execution of turnarounds
• Gain a deeper understanding of the stages, phases, milestones, outcomes of the overall process
• Apply improved and more integrated methods for planning and executing successful turnarounds
• Apply new, proven techniques in turnaround planning and management
• Develop an action plan to improve their turnaround management techniques
• Have a better understanding of their role in the process and the part of team members

Who Should Attend?

• Shutdown or Turnaround Professionals and Coordinators
• Planning / Scheduling and Cost Control Staff
• Construction Superintendents and Supervisors
• Operations Shutdown / Outage Coordinators
• Project Engineers and Contract Administrators
• Participation from Inspection, Materials, Safety and Maintenance Engineering is also encouraged

Course ContentModule (01) Introduction to Shutdowns, Turnarounds and Outages (STO)

• How STOs can contribute to the business
• Critical success factors
• The impact of STO strategy on return on investment
• Justification of the scope and timing
• Introduction to the STO life cycle phases
• STO risk management

 Module (02) Pre-Planning and Preparation for Success

• Communications and the role of stakeholders
• Organisation, roles and responsibilities
• Preparation critical success factors
• Programmed work scope identification and selection
• Corrective work scope identification and prioritisation
• Risk-based scope of work

 Module (03) Planning for Safety, Quality and Efficiency

• The critical outcomes of planning
• The 5Ms of work quality
• Work survey and analysis
• Estimating
• Hazards and contingency planning
• The use of planning libraries
• Work breakdown structure

 Module (04) Scheduling for On-Time Execution and Completion

• Scheduling concepts, terms, and standards
• Scheduling and resourcing trade-off techniques
• Scope-based budgeting
• Managing contracts and contractors

 Module (05) Staying in Control of Quality, Time, and Budget

• Work packages and logistics
• Quality planning and control
• Execution and schedule control
• Execution checkpoints
• Commissioning and start-up
• Administrative close-out, review and lessons learned