COURSE OUTLINES

Title: Managing Efficient Shutdown

Instructor: Eng. Ehab Aboward

Overview The course will provide a practical approach to managing a

successful shutdown. Over the course days the main areas of
shutdown planning and execution will be reviewed together with a
number of interactive group exercises.

Objective Upon completion of this course, participants will have gained the
following knowledge and skills

- Understand the shudow management phases

- Describe the actions needed for each phase.
- Being able to plan for a shudown maintenance.
- Idenitify the basic areas of improvement in organization shudown
management current strategy.
- Capable to use the planning and scheduling tools for shudown
time and resources mangement efficiently.
- Describe the basic reports to be collected during and after the
shutdown maintenance implementation.

Methodolgy A mix of classroom lectures, power point presentation, video

animation as well as group discussions and case studies.

Who Should Anybody from the oil & gas, petrochemicals, chemicals, power,
attend pharmaceuticals and other process industries who are involved in or
impacted by the execution of shutdowns, turnarounds and outages on
their facilities.
Current or potential future shutdown and turnaround managers
Project engineers and managers
Plant maintenance engineers and reliability engineers
Plant / operations managers
Shutdown planners and coordinators

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 TOPICS

Introduction and overview

Turnaround Overview
Shut down needs
Prevent Production interruptions
Plant turnarounds
Shut down needs
Critical elements of the turnaround
Turnaround impacts the business
Turnaround objectives
Turnaround philosophy
Turnaround management
The integration
The phases of a turnaround
What makes a successful plant shutdown?
Problems commonly encountered in shutdown execution
Successful key traits
Shutdowns Management Process Steps
The long term strategy
Need for a shutdown
Shutdown Management Team
shutdown organization
Shutdown specific goals
Milestones
Realistically Completed schedule
totalling all the submitted work
Planning and scheduling
follow-up and improvement of the overall process
Completed successfully
The Turnaround Initiating & Quality
Introduction
The 'stake holders
Policy Team
Elements interact
The purposes of the Policy/Steering team
TA quality
The 5 Ms of maintenance work quality
Auditing
Turnaround Manager
Plant safety induction
The Formal Meeting
Documentation
Conclusion
The Scope of Work
Introduction

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 Unnecessary work Methodology
cycle for work list for approval
The validated work scope
Meetings
The work list meeting
The major task review meeting
The inspection review meeting
Project work review meeting
Pre-Shutdown Work
Introduction
Pre-Shutdown Work
Long deliver items
Prefabrications
Specialist technologies
Vendors representatives
Services & utilities
Accommodation & facilities
Case study: Red Zone
Contractors
Introduction
Contractors Skim
Upside and downside contractors
Using contractors
Safety performance
Conflict between contractors
Agency labour
Contractor Selection
Contractor availability
Types of Contract
Awarding contracts
Selecting & Managing contracts
Planning
Introduction
The planning basic objective
Teams responsibilities
The Main Elements of Creating a Turnaround Plan
Major tasks
Minor tasks
Bulk work
The shutdown-start-up logic
The shutdown network
Start-up network
The constraints
Presenting the plan
Generating control documents

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 The critical path program
Shutdowns and Other Major Maintenance
Work scheduling
Turnaround organization
Organisational combinations
Who will manage the turnaround?
Who will do the work?
Basic principles
Organization Methodology elements
o The minimum number of people should be used
o A turnaround organisation is hierarchic
o One person must be in overall control
o Single point responsibility
Constraints
Policy team test the Organization
Scarce Manpower Resources
Logistics
Introduction
Planning the site logistics
The Site Logistics Team activities
Physical objects or substances
logistics office
The plot plan
Plot plan Purpose
Preparing the plot plan
Issuing the plot plan
Publish the plot plan
Turnaround safety
Hazards
Safe systems of work
Safety plan
Permit to work
Audits
Group exercise
Turnaround safety plan
Cost control and estimation
Introduction
Why estimate a cost profile?
The accurate costing
Cost elements
The exclusions
Creating a cost estimate
Manpower costs
The approved turnaround budget
Turnaround quality
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 Turnaround quality
The need for quality
Compromise plant reliability
To assure quality
Elements of quality
Quality assurance on Turnarounds
Considering joints
Possible reasons for leaks
Pressure Testing

Execution
Introduction
The event
o The routine
o The unexpected
Shutting the plant down
The turnaround manager supports
Typical faults
The shift time loss
The Turnaround Manager's Actions
Control of work
De-Isolation & Commissioning
Start up Plan
Emergency Staff
Critical path job (CPJ)
The Turnaround Management
Post-Mortem Best Practices
Group exercise: Strategic issues

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