1st Edition

Process Plants Shutdown and Turnaround Management

By Trinath Sahoo Copyright 2014
    406 Pages 4 Color & 59 B/W Illustrations
    by CRC Press

    406 Pages 4 Color & 59 B/W Illustrations
    by CRC Press

    In the process industry, shutdown and turnaround costs are responsible for an excessive amount of maintenance expenses. Process Plants: Shutdown and Turnaround Management explores various types of shutdowns, presents recommendations for better management, and offers feasible solutions to help reduce overheads. Because turnaround management is the largest maintenance activity, plant turnaround is the focal point of this text. The book details a plan to lengthen the interval between turnarounds, and curtail costs in process production management by at least 30 percent.

    This practical guidebook provides a thorough study of shutdown management, discusses different types of shutdown and managing events (emergency, unplanned, planned, and turnaround), and covers all aspects of plant turnaround management including startup, shutdown, and maintenance. It describes the five phases of shutdown management—initiating, planning, executing, controlling, and closing. It contains specific principles and precautions for successful shutdown planning, and highlights many aspects including turnaround philosophy, planning and scheduling, estimation, contractor management, execution, safety management, managing human resources, and post shut down review.

    Process Plants: Shutdown and Turnaround Management also includes topical information that readers can successfully apply to future shutdown projects. It is suitable for industry professionals and graduate students.

    Introduction

    Process Plant Turnarounds

    Activities during a Turnaround

    Maintenance Philosophy

    Economics of Maintenance Management

    Types of Maintenance Activities

    Types of Shutdown

    Shutdown of Key Refinery Units Affecting Product Pattern

    Strategic Issues

    Turnaround Evaluation

    Initiating the Turnaround

    Initiation

    Developing a Shutdown Overview

    Strategic Plan

    Establish Shutdown Charter

    Initiating

    Scope Statement

    Appoint Shutdown Team

    Major Turnaround Milestones

    What Are the Shutdown/Turnaround Performance Criteria?

    Planning

    Kickoff Meetings

    Job of Planning Team

    Planning Step One: Developing the Shutdown Work List

    Planning Step Two: Identify Task Relationships

    Planning Step Three: Manpower Strategic Planning

    Planning Step Four: Estimate Work Packages

    Planning Step Five: Calculate an Initial Schedule

    Planning Step Six: Assign and Level Resources

    Planning Step Seven: Develop Procurement Plan

    Planning Step Eight: Develop Quality Plan

    Planning Step Nine: Develop Communications Plan

    Planning Step Ten: Develop Risk Plan

    Checklist

    Information Requirements for Planning

    Planning Is Not a One-Time Event!

    Estimating

    What Is an Estimate?

    Methods for Estimating Activity Duration

    What Is the Cost Baseline?

    Shutdown Contract Management

    What Is a Contract?

    Scope of a Contract

    Parties to a Contract

    Objectives

    Contractors

    Selection of Contractor Work Packages

    Contract Types

    Selection of Contractor

    Tender Evaluation Practices

    Management of Obviously Low Bids

    Subcontracts

    Terms of Payment

    Logistics

    Shutdown Organization

    What Is Involved in Effective Shutdown Organization?

    Turnaround Steering Committee

    Determination of the Skills Needed

    Shutdown Manager’s Skill Requirement

    Leading

    Executing the Shutdown

    The Kickoff Meeting

    Safety

    Job Status Update

    Daily Schedule

    Reporting Status

    Tracking Shutdown Costs

    Preshutdown Job

    Long-Delivery Items

    Checklist

    Preshutdown

    Prefabricated Work

    Accommodation and Facilities

    Crowd Control

    Contractor’s Insurance Certificates

    Safety Training

    Employing Barricades

    Emergency Showers and Eyebaths

    Special Machines

    Vendors Representatives

    Inspection of Equipment

    Traditional Inspection Practice: Background

    Inspection of Equipment

    Columns

    Vessels

    Heat Exchangers

    Demister Pad

    Refractory

    Pressure Safety Valves

    Inspection during Fabrication of New Piping

    External Corrosion

    Approaches for Other Equipment Types

    Shutdown Safety

    Hazardous Chemicals and Catalysts

    Common Hazards

    Safety Planning

    Safety Preplanning

    Evaluation and Selection of Contractors and Subcontractors

    Emergency Warning System and Procedures

    Communication Package

    Methods of Communicating

    Conducting Meetings

    Communication for Success

    Shutdown Control

    What Are You Actually Controlling?

    What Are the Baselines?

    Measuring Progress

    Quality Plan

    Shutdown Quality

    Deliverable Quality

    Planning Quality

    Risk in Shutdown

    Why Risk Analysis Is Necessary

    What Is Risk Management?

    What Are the Basic Steps in Risk Management?

    What Is Risk Identification?

    What Is Risk Quantification?

    What Are Risk Response Strategies?

    Why Do We Have Two Separate Reserves to Take Care of the Risks?

    Using a Risk Profile

    Historical Records

    Joint Integrity

    Managing Integrity

    Major Causes of Joint Leakage

    Corrective Action for Guideline and Responsibility Deficiencies

    Joint Assembly Procedure

    Conclusion

    Commissioning

    Systematic Commissioning Planning

    Mechanical Integrity

    What to Do in Checklisting

    Commissioning

    Process Commissioning

    Commissioning and Start-Up Period

    Minimum Facilities before Start-Up

    Pre-Start-Up Safety Review (PSSR)

    Customized Testing and Acceptance Methodologies

    Sequence of Commissioning

    Equipment Operating Procedures

    Postshutdown Review

    Contract Closure

    Administrative Closure

    Postevaluation Report

    Safety/Environmental Performance and Procedures

    Shutdown File

    Final Report

    Lesson Learned Session

    Celebrating

    Performance

    Performance Measure; Success

    Lean Shutdowns: Cut Waste Wisely from Your Outages

    Appendices

    Index

    Biography

    Dr. Trinath Sahoo currently serves as senior manager at Indian Oil Corporation Limited (IOCL) and has 20 years of experience in the technical and management fields. His key areas of expertise include project engineering design and implementation, process plant maintenance, and troubleshooting and analysis of rotating equipment. Dr. Sahoo has a thorough knowledge of pump and compressor operation and maintenance; shutdown management, maintenance, and reliability; project and asset management; and advanced maintenance strategies. He has worked as a plant turnaround engineer for various projects and companies and has published papers in various international magazines and conferences.

    "This book ought to be of value to the professional engineer new to the challenges of a plant turnaround. Scheduled and unscheduled maintenance are major issues for any chemical plant, refinery or installation. The loss of production and consequently loss of revenue needs to be managed as efficiently and as effectively as possible. Correct planning and execution of a turnaround requires considerable effort to ensure efficient return to full operating capacity. This book aims to highlight the main factors that must be taken into consideration from the planning stage through to execution and post shutdown reviews."
    ––Professor Carl J Schaschke, University of Strathclyde, UK