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Shutdown / Turnaround Planning
Shutdown / Turnaround Planning
A. What is Shutdown?
Large industrial plants as are common in the chemical industry must be shut down at regular intervals to perform maintenance work in accordance with safety requirements. The whole process is described as shutdown and turnaround and begins with switching off plant and equipment. The inspection and servicing can then be carried out and finally the plant has to be started up again
B. Phases of Shutdown Project
The typical Shutdown project has following Phases
Pre Shutdown :
This is the phase where all preparatory work is carried out before shutdown starts, It includes activities like
- a. Mobilisation of Manpower, Materials and Machineries
- b. Safety Training
- c. Welder Qualification
- d. Scaffolding
- e. Identification of Blinds
- f. Bolt Servicing
- g. Pre-fabrication etc.
Decommissioning:
This is the phase where the Oil is taken out, the plant is slowly shutdown and gases are removed. The plant is safe to carry out Hot work and opening of manholes etc.
Shutdown:
This is the phase where actual maintenance is carried out. Critical equipments activities are as follows
a. Columns
- Blinding
- Steam-Out
- Manway Opening
- Erection of Scaffolding
- Initial Inspection
- Tray Dismantling and Assembly
- Repairs if any
- Internal Cleaning
- Final Inspection
- Removal of Scaffolding
- De-Blinding
b. Heat Exchangers
- Blinding
- Cover Opening
- Dismantling
- Bundle Pulling
- Hydroblasting
- Bundle Insertion
- Initial Shell Test
- Initial Tube Test
- Final Shell Test
- De-Blinding
c. Vessels
- Blinding
- Steam-Out
- Manway Opening
- Erection of Scaffolding
- Initial Inspection
- Repairs if any
- Internal Cleaning
- Final Inspection
- Removal of Scaffolding
- De-Blinding
d. Piping
- Blinding
- Steam-Out
- Repair (Welding)
- Non Destructive Testing (Radiography)
- Inspection
- Hydro testing
- Final Inspection
- Painting or Insulation
- De-Blinding
e. Process Valves
- Blinding
- Dismantling
- Transport to Workshop
- Overhauling & Repair
- Hydro testing
- Transport to Plant
- Assembly
- De-Blinding
f. Instruments (FE, TW, CV etc.)
- Blinding
- Dismantling
- Transport to Workshop
- Calibration & Repair
- Transport to Plant
- Assembly
- De-Blinding
g. Painting
- Erection of Scaffolding
- Scrap Cleaning
- Initial Inspection
- Primer and Painting
- Final Inspection
- Removal of Scaffolding
Start up and Commissioning:
The plant is safe and ready to take the oil in for processing.
C. Inputs for Preparation of Schedule
- Scope of work
- Clients Input
- Execution strategy
- Intermediate Milestones
- Equipment List
- Inputs for Area In charge
- Reporting formats from Client
- Prepare a sample schedule
- Decide on Activity Codes
- Updating Frequency
- Type of manpower
- Manpower Requirement for each Activity
- Subcontracting jobs
- Major Equipment Movements (Cranes)
- Safety Requirements
D. Schedule Preparation
- Scope of work
- Clients Input
- Execution strategy
- Intermediate Milestones
- Equipment List
- Inputs for Area In charge
- Reporting formats from Client
- Prepare a sample schedule
- Decide on Activity Codes
- Updating Frequency
- Type of manpower
- Manpower Requirement for each Activity
- Subcontracting jobs
- Major Equipment Movements (Cranes)
- Safety Requirements
E. Updating and Reporting
- Updating the Schedules based on the inputs from Supervisors from Site.
- Updating S-Curves
- Finish date variance reports - Schedule
- S-Curve Planned v/s Actual
a. Planned v/s Actual for the period
b. Planned v/s Actual Cumulative - Manpower deployment
- Constraints for the Day
- 24hours Look Ahead Schedule
- Daily Progress Reports
- Catch Up Plan
- Distribution of Reports
F. Things to Remember
- Work Safety
- Use proper Safety gears like (Safety Shoes, Helmet, Gloves etc.)
- Don’t Work without Work Permits
- Good Housekeeping
- Adhere to the Schedule
- Plan your activities 24hrs in Advance
- Be ready for Discovery work
- Complete the activities on their Early dates (Target early Completion)
- Utilise Manpower very efficiently
- Report Progress on Time
G. Offerings from Project Baseline Consultants
- Recommendation of IT Infrastructure for PMO Set-up
- Study the scope and Prepare the Schedule
- Meeting with client for Baseline Signoff
- Schedule Updates and Reporting
- Monitoring and Controlling (Catchup Plan, Look Ahead Schedules etc.)
- Effective Communication to all the Stakeholders
- Presentation