Owing to the heavy impact of plants shutdown for controlling and repairing oil refinery equipments both in terms of production loss and of major maintenance. Safety practices for a successful plant shutdown craftforce. Post shutdown activities and completion of the shutdown report phase one. Chapter 1 management of shutdown and turnaround 1 1. It provides a loose guideline for structuring a project management methodology.
As with non shutdown maintenance, the single biggest factor that impacts shutdown management is the operating schedule. Trying to blindly apply the same practices wed use for one kind of project management into a shutdown might have disastrous consequences. Keys for effective shutdown management who should attend this training is designed to be beneficial for all staff both the owners and contractors who are involved in. Shut down management for coal handling plant of thermal power station a new approach by makarand joshi 1. The old cliche that if we do a good job in execution, the cost will take care of itself still influences shutdown and turnaround management thinking. Sap project systems plant maintenance utilization for plant wide shutdown.
Depending on the technology of the plant, the turnaround frequency varies from once a year to once in six years. Consultant on tpm, rcm, shutdown management, project management, plant reliability, root cause failure analysis, pump, compressor and turbine maintenance and overhauling expert. An effective method is developed for shut down management of coal handling plant of thermal power stations. Originalityvalue the approach in the paper adds important knowledge on shutdown maintenance drivers and how they relate to the organizations operational strategies. Asset manager improving shutdown management plant services.
There is a world of resources out there, however, with tips, insights, and management strategies for getting the job done right. The core shutdown team is responsible for development and implementation of the detailed plan. Plant shutdowns preparation management control turnaround management sede legale. A request was made to the shutdown management that observers were kept on, but a few observers were still lost due to demanning and nightshift work. Managing a successful temporary plant shutdown and return. Managing shutdowns is a complex process which firstly requires extensive experience of the particular process plant to be shut down. Historically, shutdowns and turnarounds have been driven by schedule performance rather than costs. The single best thing you can do for a successful plant shutdown.
Turnaround, shutdown and outage management 1st edition. The words plant shutdown even if referring to a temporary one can be associated with a long litany of negatives. Turnaround, shutdown and outage management sciencedirect. The project management institute pmi has published a guide to the project management body of knowledge pmbok to identify and describe the subset of the project management discipline that is applicable to most projects most of the time. Maintaining wastewater treatment plant operating efficiency. The shutdown team should include senior representation from maintenance, operations, engineering and finance including capital planning and purchasing. The organization of plant turnaround maintenance in. Bsafe applied to a maintenance shutdown at ici wilton. Trinath sahoo with large amounts of revenue at stake, process industries are focusing more on turnaround management. Turnaroundshutdown optimization plan for the 5 phases of a.
Planning for the possibility of a plant shutdown can certainly be a challenge, but keeping these tips in mind can be immensely helpful when and if things come grinding to a halt. 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. Planned shutdowns usually involve closing the entire plant. Kevin duffyvice president of operational excellence for kepnertregoe kt offers an indepth look at outage management in his contribution to reliable plant. Scheduled shutdowns, outages, and turnarounds are a big deal. Loss of control to september safety subsystem of risk shutdown operate the plant and make changes in a 1st, 2005 reliabilityspeed acceptance at timely manner aefba2004steam non compliance absa restrains us from fall 2006 asap legal shutdown. Mar 28, 2016 process plants shutdown and turnaround management charles smith. Attempt to anticipate unexpected events and identify and minimize all. Pr slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Pmaops411b manage plant shutdown and restart modification history not applicable.
Shutdown maintenance drivers under an integrated and business. To fix it, the plant must be shut down quickly in a controlled way full and partial shutdowns. Describe typical turnaround management techniques coordinate a simple turnaround project from planning to execution and handover coordinate the personnel in a shutdown and turnaround project apply shutdown best practices and planning build an effective maintenance project plan for shutdowns. Shut down can be defined as scheduled down period for a plant for scheduled maintenance for an extended period of time.
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 for shutdowns, turnarounds and outages training after attending this 3day course, you will save time and money on your next shutdown. A documented procedure, communication, and welltrained team are key. Historically the maintenance manager has managed the shutdown with little or no project management. Shutdown and turnaround clients the solution emerald s toolkit includes state of the art software that covers planning, scheduling, resource leveling, progressing, 4d simulation, monte carlo risk analysis, and earned value analysis. Shutdown coordinatorsplanners shutdown leader plant owner your shutdown management team. Marketing might be involved to ensure customers are serviced adequately during the shutdown period. Shutdown and turnaround management explores various types of shutdowns, presents recommendations for better management, and offers feasible solutions to help reduce overheads.
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. 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. A well documented shutdown that runs smoothly can be a valuable resource for the future. How to convert pdf to word without software duration. Access to these plants and equipment is usually restricted during routine operations, so planned shutdowns provide the opportunity for the engineering team to complete major maintenance. A leaking pipe or a catastrophic equipment failure usually happens when you least expect it and usually at the worst time possible. The authors focus is on ending the business relations with suppliers, through developing an ending competence for the. It is the activity that most determines the success. It can able to achieve the schedules that are planed. The aspects that should be considered include design, procurement, operations and. The shutdown involved the inspection, replacement or repair of those components that were worn or damaged or where their expected remaining life was less than 35,000 hours of use. Nov 01, 2016 a successful plant shutdown starts with a safe workforce. Because turnaround management is the largest maintenance activity, plant. Monitoring plant shutdown and turnaround performance needs a mix of lagging and leading measures and indicators.
An emergency shutdown is any shutdown required to avoid immediate risk of injury to persons andor serious damage to the physical plant or the research work being conducted at nih. Standard shutdown management kpis tend to be historic measures of turnaround goal achievement, but it is also necessary to have predictive indicators of shutdown. If turnarounds are not properly planned, managed and. Planning for shutdowns and outages life cycle engineering. Project management solutions that deliver results emerald. The additional resources and other costs associated with the shutdown make it a very expensive endeavor.
This course is 85% concerned with the time before the shutdown begins. Stopping production, no matter the duration, results in decreased revenue. Cycle makeup system in operation if the liquid level of tanks, vessels and basins is lower than those required, filling shall be. Process improvement for power plant turnaround planning and management. In the event of an actual shutdown where sec is required to implement this general guidance, supplemental governmentwide guidance issued by the office of management and budget omb, the office of personnel management opm, and the general services administration gsa will also apply. Our technical group can integrate our systems with cmms or eam systems and can provide data conversion from. Prerequisites a basic knowledge of maintenance management on a plant. Shutdown and turnaround management is a key function in all industry setups. Practical shutdown and turnaround management for engineers. Shutdowns have a profound ability to affect the plants financial future in either a.
May 09, 2020 keys for effective shutdown management who should attend this training is designed to be beneficial for all staff both the owners and contractors who are involved in the planning, coordination and execution of stos. Pdf turnaround maintenance management in a processing. Singh 2000 the challenges faced by shutdown management. Unit descriptor unit descriptor this unit covers the coordination of the shutdown and restarting of a production process in a safe and efficient manner due to a planned or an unplanned shutdown or emergency situation. Effective plant shutdown, turnaround, and outage sto management important course work very important pre to wrapup this trueworkshop delegates will draw up specific improvement plans to address their top 5 areas for improvements in power point format. The goal is to achieve implementation when they return to their organizations. Within this document, turnaround is also intended to reference the entire span from preturnaround preparations to shutdown to execution to startup. Scheduled shutdown maintenance linkedin slideshare. Process plants shutdown and turnaround maintenance and management explores various types of shutdowns, presents recommendations for better management and offers feasible solutions to help reduce overheads. Plant shutdowns, also known as turnarounds, are one of the most critical times in the operation of a plant. In the process industry, shutdown and turnaround costs are responsible for an excessive amount of maintenance expenses. A successful plant shutdown starts with a safe workforce.
Because turnaround management is the largest maintenance activity, plant turnaround is the focal point of this text. Under the current economic climate, many mills are experiencing more frequent andor longer production outages. During extended down times, the mill sends little or no food to the microbiological population bugs resulting in a gradual depletion of the. Because shutdown cost for a petroleum refinery is normally 30 percent higher than annual maintenance costs, this book details how to manage the more favorable turnaround option. Process improvement for power plant turnaround planning. Effective plant shutdown, turnaround, and outage sto management. Plant shutdown turnaround management monitoring kpi key. The shutdown manager evaluates the actions to be made, builds a planning team, involving the technicians of the various plant functions. Facility or planned shutdown maintenance is vital for any production facility. If you continue browsing the site, you agree to the use of cookies on this website. Shutdown management is project management of a special kind. Turnaroundshutdown optimization plan for the 5 phases of. Towards the end of the shutdown some problems did start to occur when contractors started to trim down their resources. The organization of plant turnaround maintenance in processbased industries.
Manufacturing and process plants, computer systems, airliners, and many other systems must be regularly closed down or taken out of service for planned maintenance operations. A global mining group conducted a shutdown and major overhaul of a large item of production plant to maintain its availability and operational utilisation. Health is viewed within the framework of a generic management. Applying pmbok to shutdowns, turnarounds and outages. He has 17 years of technical and engineering management. Jul 09, 2014 on april 15, 1981, the owner or operator of a hazardous waste management facility must have a written closure plan. It is only when it can forecast with some degree of certainty. 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. 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.
But the wastewater treatment system is a living organism, requiring a constant food source to remain viable. Accountability and specific responsibility for key shutdown roles. Oil refinery turnaround main goal is to respect the maintenance schedule in terms of times and costs as defined by the management. 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. Pre shutdown activities planning and scheduling confirm who must do what.
The author explores different aspects, including philosophy, planning and scheduling, estimation, contractor management. In a coal handling plant of thermal power stations there are different streams for transporting of coal up to bunker. 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. Day of the shutdown personincharge conduct a prejob walk down of the mop and rehearsal meeting with vendors. Systematic and planned power shutdowns not only save equipments but also enhance their life. Ci for turnaround management in an oil r efinery 531. Planning and managing power shutdowns, power outages and turnarounds are a complex and highly demanding function in a factory or office environment. Introduction planning and managing shutdowns, turnarounds and outages in the process plant environment is a complex and demanding function. Process plants shutdown and turnaround management youtube. Shutdowns have a profound ability to affect the plants financial future in either a positive or negative way.
As with nonshutdown maintenance, the single biggest factor that impacts shutdown management is the operating schedule. Apr 23, 2012 scheduled shutdown maintenance what drives or justifies a shutdown. He has 17 years of technical and engineering management experience in the largest public sector oil. The single best thing you can do for a successful plant shutdown is to give yourself enough time to plan the outage effectively. Until final closure is completed and certified in accordance with rule 3745 6615 of the administrative code, a copy of the most current closure plan must be furnished to the director upon request, including request by mail. Lessons learned from a major plant shutdown broadleaf. Oct 25, 2016 having a strategy for managing your shutdown, turnaround, or outage is key to a jobdonewell. Introduction planning and managing shutdowns, turnarounds and outages in the process plant. The plant turnaround maintenance is a maintenance activity in which the machinery and equipment of the plant are shut down for repairing the worn out parts or installing new. The following are some of the best safety practices for a successful plant shutdown. Plant turnaround management programmed plant shutdown. Because turnaround management is the largest maintenance activity, plant turnaround. For each project management environment you are confronted with, you must look at it for the particular business challenges it represents, and bring forward the tools that are appropriate to those challenges.
Process plants shutdown and turnaround management charles smith. Emphasis on planning, programming, maintenance activities execution and control to obtain the lowest cost, planned and achieving required quality and safety standards. The remaining 15% is the execution tactics to keep the project on course. Ensure valuable stock and equipment is kept in secure areas of your premises, especially following deliveries during holidays.