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Circle Circle
RMA - 01
5 days
Doha
9 January, 2022
10900 QAR

Strategies to Optimize Shutdowns, Turnarounds & Outages Virtual

Course Overview:

Planned shutdowns are an accepted feature of large process and production plants but, if poorly managed, can significantly affect overall plant availability and business profitability. There is a wide gap in performance between the average performer and the best. However there are approaches, tools and techniques readily available to be deployed; and they have been shown to be successful.

It will provide participants with the necessary philosophies, approach, framework, tools and techniques to enable them to participate effectively in managing the total shutdown business process at a world-class level, In particular the emphasis will be put on identifying and placing the key decisions in a business rather than an engineering or production perspective.

Course Objectives:

Upon completion of this course, the trainees will be aware and understanding of the following:

  • Identify actions which will help to delay or avoid a shutdown
  • Justify the reasons for a shutdown in business terms (increased availability, efficiency and/or integrity) and establish shutdown objectives and targets
  • Communicate shutdown goals through the organisation, gain alignment and drive the shutdown process effectively
  • Vet, challenge and freeze shutdown work scopes to produce minimum work volume work packages
  • Benchmark their own companies against top performers; identify recipes for success, performance shortfalls and the reasons for them.
  • Set a framework to create the shutdown business process in terms of people and their responsibilities activities and identification of key events
  • Create an integrated plan for minimum duration
  • Create an effective contracting strategy
  • Gather performance data to drive an improvement process
  • Have a much clearer understanding of their own and every other team members role in ensuring a successful turnaround

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 Outline:

Module (01) Role of Maintenance Shutdowns & Turnarounds in World-class Organizations

  • How shutdowns and turnarounds can contribute to the business
  • Key success factors
  • The three critical paths of shutdowns and turnarounds
  • The difference between shutdowns and turnarounds and projects
  • Shutdown and turnaround return on investment
  • Shutdown and turnaround management self-assessment
  • The shutdown and turnaround phases
  • Reasons for shutdowns and turnarounds
  • Success Factors

 Module (02) Shutdown/Turnaround Preparation

  • Risk management
  • Justification requirements
  • Communications to stakeholders
  • Shutdown roles and organisation
  • RASCI matrix for shutdown
  • Preparation critical success factors
  • Identify routine PM to be included in scope
  • Identify routine condition based tasks to be performed prior to shutdown and turnaround
  • Identify function testing to be performed at conclusion of shutdown and turnaround

 Module (03) Shutdown/Turnaround Preparation continued

  • Apply CBM and degradation analysis to create scope visibility
  • Apply notification process to manage create scope visibility
  • Apply risk-based task selection methods to prioritise and challenge scope
  • Review, approve, communicate and freeze the scope
  • The critical outcomes of planning
  • The 5 Ms of maintenance work quality
  • Job analysis and scoping
  • Estimating
  • Risk and contingency planning
  • The use of planning templates
  • Work breakdown structure

 Module (04) Shutdown and Turnaround Schedule

  • Terms and concepts of scheduling
  • Network display methods
  • Apply CPM
  • Identify resource constraints
  • Resource requirements based on CPM
  • Resource smoothing
  • Resource balancing
  • Optimized resource profile
  • Shutdown and turnaround budgets
  • Assign Shutdown Work – In-house and Contractors
  • Types of contractors
  • Types of contracts and criteria for selection
  • Risks associated with the use of contractors
  • Benefits of using contractors on shutdowns
  • Staying in control of the contractor

 Module (05) Shutdown and Turnaround, Execution Control and Review

  • The shutdown package
  • Shutdown quality control
  • Shift schedules
  • Preparing equipment for the shutdown
  • Daily schedules
  • Dealing with emergent and additional Work
  • Control data
  • Status accounting
  • Control the Shutdown
  • S-curves
  • Earned-value
  • Shutdown performance indicators
  • Shutdown and turnaround review meeting agenda
  • Why shutdowns fail
  • Problems in shutdowns and their origins
  • Start-up and commissioning
  • Shutdown close-out reporting and review
  • Shutdown closing out report
  • Shutdown closing out review
  • Overview of computerized tools
Qatar Skills Training Centre
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