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 Managementalso includes topical information that readers can successfully apply to future shutdown projects. It is suitable for industry professionals and graduate students.
Table of Contents
Process Plant Turnarounds
Activities during a Turnaround
Economics of Maintenance Management
Types of Maintenance Activities
Types of Shutdown
Shutdown of Key Refinery Units Affecting Product Pattern
Initiating the Turnaround
Developing a Shutdown Overview
Establish Shutdown Charter
Appoint Shutdown Team
Major Turnaround Milestones
What Are the Shutdown/Turnaround Performance Criteria?
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
Information Requirements for Planning
Planning Is Not a One-Time Event!
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
Selection of Contractor Work Packages
Selection of Contractor
Tender Evaluation Practices
Management of Obviously Low Bids
Terms of Payment
What Is Involved in Effective Shutdown Organization?
Turnaround Steering Committee
Determination of the Skills Needed
Shutdown Manager’s Skill Requirement
Executing the Shutdown
The Kickoff Meeting
Job Status Update
Tracking Shutdown Costs
Accommodation and Facilities
Contractor’s Insurance Certificates
Emergency Showers and Eyebaths
Inspection of Equipment
Traditional Inspection Practice: Background
Inspection of Equipment
Pressure Safety Valves
Inspection during Fabrication of New Piping
Approaches for Other Equipment Types
Hazardous Chemicals and Catalysts
Evaluation and Selection of Contractors and Subcontractors
Emergency Warning System and Procedures
Methods of Communicating
Communication for Success
What Are You Actually Controlling?
What Are the Baselines?
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
Major Causes of Joint Leakage
Corrective Action for Guideline and Responsibility Deficiencies
Joint Assembly Procedure
Systematic Commissioning Planning
What to Do in Checklisting
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
Safety/Environmental Performance and Procedures
Lesson Learned Session
Performance Measure; Success
Lean Shutdowns: Cut Waste Wisely from Your Outages
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