what is a turnaround in a plant

So, its important to have a variety of parts, tools, and equipment on hand before the project begins. Internal plant personnel who will be involved in turnaround projects can also benefit from a training refresher, so consider partnering with a supplier to review a variety of installation basics. Only allow the use of high-quality parts and componentsthis will help make your turnaround more effective. According to TA Cook and Solomon Associates (2019): If these statistics illustrate one thing, it is that there is a lot of dissatisfaction and room for improvement when it comes to the performance of turnaround projects. The trick is balancing the need for basic parts while avoiding the pitfall of unused inventory. An important part of this process is feedback sessions about the work to gather information for next time if it is a repetitive job (as many are). Companies can augment a turnaround maintenance team capabilities in three ways: A leading international rubber and polymers player uses a combination of formalized training, on-the-job experience, and hiring to build capability. Turnarounds often throw up more issues than anticipated, making them difficult to keep on track, and requiring very experienced managers. Turnaround maintenance management encompasses first planning for the shutdown, then procurement of equipment, materials and expertise, and finally execution of the event. They present a unique set of challenges, and the stakes are high. Maintaining tight quality control is an essential component in a successful turnaround project. This final review phase is when you answer these questions and hopefully streamline your processes for the future. Before planning or implementing a shutdown or turnaround, all interested parties should be contacted and involved opening communication across the business and beginning the process of identifying the scope of the project. Such concerns may cause minor or major delays to either the execution or the scope of the project. We recommend building a skilled technical team with experience across multiple turnaround maintenances. This means that facilities are scoping based on hopes and assumptions rather than data and calculation and this can be a dangerous starting point to work from. Where things go wrong is when you step below this level and begin to pull individual processes or pieces of equipment into the scope to decide what must be done to those during the outage. It's common for operations to stop for maintenance, cleaning, equipment replacement, repair, upgrade resources, or to maintain regulatory compliance. What would your organization look like if over 80% of your work orders did not satisfy requirements? Let us take a deeper look into specific turnaround phases and how they can be optimized. a turnaround thats too long or exceeds its budget could result in the company reporting a financial loss. Potlatch Cloquets low-cost maintenance shutdown management techniques focusing on type, quality, and timing of work contribute to an 83% drop in maintenance cost per ton. Plant turnaround planning is a process that requires strategy and careful execution that sees project success to fruition. As a result, it helps to have a variety of hoses, valves, and adapters on hand before the project begins. This process can be one of the biggest challenges that asset owners face. As an organization, its important to define turnaround objectives. Setting goals, developing strategies, defining tasks, and creating schedules form the basis of turnaround development and success. As summarized in Figure 2, they span all five components of turnaround maintenance planning and address the common challenges. A Shutdown, Turnaround, or Outage (STO)three terms that mean the same depending on the industrial sector we are acting inis an event in which an industrial plant or some process units are decommissioned for a planned period to perform maintenance, inspection, regeneration, or revamp. According to the Risk Based Work Selection process, the risk of not doing the work is too high so it must be done there is no history available on the failure. Integrate and unify existing tools and introIntegrate and unify existing tools and introduce new ones as needed to assist the turnaround maintenance process. Strain is increased on other suppliers to meet demands, and turnarounds which become shutdowns can be catastrophic for supply at a regional level. In this phase, your organization identifies the work that is critical to support production reliability. Creating a process with common goals is vital to achieving world-class reliability and maintenance. Turnaround Project Planning Primer - Turnaround Organization Reach Oil & Gas professionals through cost-effective marketing opportunities to deliver your message, position yourself as a thought leader, and introduce new products, techniques and strategies to the market. Work Order #2: 600-megawatt combined cycle power plant steam turbine (same plant). This is where mistakes happen: assets are missed, machinery condition is misunderstood, or the work sequence is wrong and requires rework. Is there anything you learned from the operation? It wastes time if this must be done during the meeting. IDCON provides common-sense consulting & training so your maintenance team can keep equipment running. Learn about managing everything from assets to engineering documents to workplaces. Here. The risk of not doing the work is too high based on the history of breakdowns of the steam turbine; it cannot be deferred to the next shutdown; the work can be executed economically and safely outside the outage (the spare pump is in place; approved ship is in place within region with two weeks turnaround); the work scope cannot be reduced; the work item does not remain in the outage scope. Those are the Execution phase and the Critique phase, you can learn more about these two phases in our book Shutdown Turnaround Optimization Process A practical guide or by attending our training course either at your site or our HQ. Having this information ensures that the right work is being done during the shutdown and that the problem needing solving is understood. The importance of turnaround maintenance to plant safety and uptime has insulated it to some extent from normal reengineering and budgeting efforts. At best, only approximately 32% of turnaround maintenance meet these criteria. Manufacturing, May 16, 2021 This reflects the substantial hit to profitability associated with every day a high-margin plant is shut down. If a problem or delay does occur, resolution will be much easier if youre in consistent communication with shareholders. This group provides an external, unbiased point of view across the turnaround maintenance process, timelines, critical paths and resources, and an independent assessment of readiness, informing the final Go or No-Go decision 6 months prior to the turnaround maintenance. 2023-06-01 Oil & Gas Turnarounds and Shutdowns - Intricate Planning begins years in advance, with the shutdown itself taking anywhere from a few weeks to a few months. Boston Consulting Group 2023. Moving components and expertise across national borders is fraught with delay and difficulty. But opting out of some of these cookies may have an effect on your browsing experience. The turnaround maintenance team tracks progress against the KPIs and reports regularly to the steering committee. Get the details on Maintenance Connection's industry-leading, data-backed software solutions. One leading global petrochemical companys typical turnaround maintenance organization, shown in Figure 3, illustrates many features of an effective project structure. See also:report on staffing and managing shutdowns and turnarounds. If the entire plant needs to be maintenanced, turnaround time will refer . Late start-ups make it impossible to complete work on time. A base analysis of a refinery will give an overview of the scope and duration of any shutdowns and turnaround needed. From oil and gas to refining and chemical processing, a plant turnaround (or shutdown) is an inevitable reality in most industries. These are just some of the common challenges that organizations like yours face during each phase of the turnaround process. And budgeting far enough in advance to secure the best prices is especially important. Quality control over parts and equipment is essential to executing a successful turnaround. In the six months following this scope challenge then freeze, any additional work requests are subject to intense evaluation. We respect your privacy, by clicking 'Subscribe' you will receive our e-newsletter, including information on Podcasts, Webinars, event discounts, BCG was the pioneer in business strategy when it was founded in 1963. They happen when power supplies are interrupted, equipment breaks down, or deliveries fail to arrive. Because of its profound impact on both successful procurement and execution, the focus of this paper is the turnaround maintenance planning process and key best practices for each component. Plant turnarounds achieve operational excellence Certain issues can't be solved while the plant is still up and running. Organizations should have: If the turnaround is large enough, there will be many outside contractors involved and if there is a lack of organization, it is impossible for them to be efficient and beneficial to your organization. Tasks should be prioritised and scheduled, before the viability of the project can be assessed. There are normally two phases in turnaround planning: strategic and detailed. Any cookies that may not be particularly necessary for the website to function and is used specifically to collect user personal data via analytics, ads, other embedded contents are termed as non-necessary cookies. This will allow a company to learn from any mistakes, and to have a plan laid out years in advance. Your organization must identify the business requirements and drivers. A turnaround is a scheduled stoppage of part or all of a plant's day-to-day operations. Some organizations have both Major (more than 24 hours) and minor (24 hours or less). Plant turnaround or plant shutdown is both an inescapable reality and a common occurrence in many asset-heavy industries. What is scheduling exactly? How to Plan for a Successful Plant Turnaround - Total Safety As a consequence, inconsistent part quality brings about unpredictable performance, unnecessary maintenance requirements, and possible downtime. Execute an effective plant turnaround in seven easy steps After planning, especially for a major outage and turnaround, it is best practice for the maintenance manager or department manager to review all job plans, specifically if they involve the critical path, and to give feedback to the planner. With the world now completely reliant on oil and gas, planned cessations are a necessary part of the refining process. Our annual user conference is back in person! Today, thanks to advances in equipment reliability and maintenance programs, turnarounds happen less often than before. Here, it is important to keep in mind that many process-heavy facilities have defined turnaround intervals for each of their process units (e.g., unit 21 has a turnaround once every nine years, maximum). That said, a lot of the relevant data is often missing, meaning it cannot be leveraged to develop a plan. to find out how we can help you be mission ready. There are a few key areas to focus on when proceeding with an STO. Both types are important, with the process KPIs acting as leading indicators for the outcomes and offering insights into areas for improvement. This website uses cookies to improve your experience while you navigate through the website. Plant Turnaround and Plant Maintenance | Storee Construction Shutdown schedule compliance, Proactive Approach to Shutdowns Reduces Potlatch Maintenance Costs, A Helpful Guide for Using CMMS Codes in Maintenance, Setting Disciplined Priorities when Prioritizing Maintenance Work, https://www.youtube.com/watch?v=ArLjqb1Zn_U, Not planning for or meeting market or seasonal demand, Equipment deterioration and maintenance demands, i.e., Major Maintenance, Capital project opportunities not identified. The turn- around maintenance team and steering committee share the same set of KPIs and are jointly responsible for meeting them. What is the purpose of the Planning Phase in Shutdown/Turnarounds? When weve been at client sites, we often hear that Shutdown/Turnarounds arent managed well. When many, A Maintenance Planning and Scheduling Perspective Priority, as defined in the Franklin Dictionary, means coming before in time, order, or importance. When prioritizing maintenance work, one must consider its importance. If major maintenance items that need a shutdown arent done, such as boiler inspections and pressure valve testing, production losses will occur due to break-in and emergency work to fix problems. Refineries and chemical plants do not undertake plant turnarounds lightly due to their inherent complexity. Why or why not. Our experienced professionals will work with your operation to decrease turnaround periods and lower costs at any location. Turnarounds provide an essential opportunity for various maintenance issues to be identified and resolved. Boston Consulting Group partners with leaders in business and society to tackle their most important challenges and capture their greatest opportunities. That way, anyone working on the turnaround will be required to have the same baseline knowledge and will be cognizant of sound installation best practices. Best practice is to have at least two months cutoff time for an annual shutdown or turnaround. Consistent specifications will reduce the intermixing of parts from different suppliers, making the job of keeping the systems in working order much easier in the future. Plants that have already reached out to their vendors ahead of time see tip #1 are at an advantage and can enhance their outcomes by engaging their vendors for expert recommendations on system improvements. Scope challenge must be deployed before scope freeze, to ensure that the jobs included are both comprehensive and sharply turnaround maintenance focused, and then post-freeze to evaluate any additions for approval. The first is a clear and thorough job description including job steps so that crafts can perform the work safely and efficiently. At IDCON, we divide plant Shutdown and Turnaround management into 6 phases. Extending turnaround activities may result in fuel shortages, price increases, or both. Turnaround is a blanket term that encompasses more specific terms such as I&Ts (inspection & testing), debottlenecking projects, revamps and catalyst regeneration projects. These multi-year arrangements include external contracts for core manpower services such as scaffolding, welding, cleaning, and hydro- jetting. Instrumental in guiding and regulating the turnaround maintenance process, the right KPIs can ensure sharp oversight and accountability and align objectives across multiple stakeholders. It is mandatory to procure user consent prior to running these cookies on your website. A good tip is to enlist the help of suppliers and partners early in the turnaround process. Search Products And Discover New Innovations In Your Industry. Strategic planning involves an overview of what will take place and how objectives will be accomplished. Asset Integrity Management Expecting Stormy Waters? For many, turnaround maintenance represents a rich and untapped opportunity. Along with planning a turnaround strategy, its key to share facets like objectives, project preparation schedule, and dynamic risk management initiation with stakeholders. - Managing Editor, Digital , Charlotte Business Journal. Turnarounds also vary of duration, typically lasting between 2 weeks and 2 months depending on the industry, plant, and other variables. On the other hand, a turnaround thats too long or exceeds its budget could result in the company reporting a financial loss. How to Have a Successful Plant Turnaround: Challenges and Strategies Headcount reductions have created gaps in knowledge and continuity. There needs to be communication in terms of the production interface. Complete the evacuation, cleaning, and housekeeping procedures to allow uninterrupted operations post-start. See also: shutdowns and turnarounds in the oil and gas industry. Update all impacted Standard Operating Procedures (SOPs). Executing the Scheduling Phase correctly will result in shutdown preparedness, efficient and high-quality work, better communication, developed contingency plans, and resource leveling and scheduling. They are most plants largest maintenance activity in terms of time, cost, and manpower. As shown in Figure 4, KPIs may be linked to outcomes or processes. What can you do to standardize installations and ensure proper practices are used across the variety of contractors working on the turnaround? Get the latest news on Accruent solutions, events and the company at large. Work is added into the schedule too late. If executed correctly, the Planning Phase will result in downtime reduction, mitigation plans, the most critical jobs being planned first, and contracted jobs being planned. Those delays lead to significant revenue reduction as affected plants cannot get started quickly or efficiently. They do not know what the equipment looks like or how it is performing. They are exclusively dedicated to a given turnaround maintenance for the entire duration of its planning and execution. A turnaround (commonly abbreviated TAR) is a scheduled event wherein an entire process unit of an industrial plant ( refinery, petrochemical plant, power plant, pulp and paper mill, etc.) Thanks to the large and complex nature of fluid systems in chemical plants and refineries, it is difficult to know the precise number and nature of the components that will be needed during a typical turnaround. Plants are long-term assets, designed to operate for 10, 20, 30 years. There needs to be a process in place to screen and evaluate risk or else work that doesnt need to be included in the shutdown may be added, wasting time. Improving systems does not happen by chance. In addition, plant turnarounds often require facilities to halt production. Waiting for a single part can cause significant progress delays. The review phase involves reporting, system performance analysis and debriefing on the shutdown process as a whole. So, its important to have a variety of parts, tools, and equipment on hand before the project begins. The goal for all types of interruption should be to achieve a return to normal process within time (difficult in outages), on budget, with no harm to staff, and with as little unplanned work as possible. View previously recorded webinars to drive value for your organization. You want to avoid ordering certain parts one the project has started. For example, training on fluid system installations may include a review of basics such as how to properly prepare and bend tubing, as well as best practices for tightening and inspecting fittings. A turnaround is a scheduled stoppage of part or all of a plants day-to-day operations. If you need help. duration, cost reduction, quality targets, etc), preliminary scope, and initial team selection, especially the turnaround maintenance project manager. A turnaround that stays within budget and timeline can have a positive effect on a plants overall efficiency and safety. Impacts of the decision to advance or delay one plants turnaround maintenance are visible throughout the plant portfolio. The work list determines the total shutdown scope. How long did a work order take? During a shutdown, its crucial to prepare as much as possible to help minimize potential challenges. A turnaround which is sometimes referred to as a TAR is a highly-expensive planned period of regeneration in a plant or refinery. A plant turnaround is a major endeavor. Companies frequently skimp on their post turnaround maintenance analyses and activities. While some have clawed back a recovery, others remain down. Before restarting the plant, ensure all critical jobs are completed, as well as pre- startup safety reviews. Register before May 31 for a $250 savings. online learning opportunities and agree to our User Agreement. What is a Plant Turnaround? Challenges and Ensuring Compliance. On the other, it is critical to establish a solid planning process to minimize such changes and limit extra costs arising from modifications after the scope freeze. This can be accomplished in two ways. Using these best practices as your guide can help your plant turnarounds go much faster and more efficiently, while also enabling the potential to upgrade the long-term dependability and performance of your fluid systems. Online. Employees and contractors work (sometimes around the clock) to get everything ready for the plant to resume its regular operations. with turnaround maintenance experience in its training efforts. What You Need to Know About Industrial Shutdowns & Turnarounds Tack, Manage And Analyze Asset Performance And Cost Through The Lifecycle, Identify And Resolve Problems Before They Arise With Comprehensive Data, Maximize Uptime And Streamline Proactive Operations In One Centralized Tool, A CMMS Works to Centralize Information, Automate Tasks And Improve Efficiency, Increase organization and operational efficiency, PM Software Can Facilitate Preventive Scheduling And Maximize Uptime, Streamline Repairs, Optimize Workflows, Maximize Productivity And More, A Comprehensive, Multi-Site Tool Simplifies The Work Order Management Process. Figure 5: Vendors that offer localized support can often deliver parts in a timelier manner sometimes within a day or less to help keep turnarounds on schedule. Both tasks were delayed because they cant be completed on the same machine at the same time. It is good practice to use a template when planning jobs, whether it is daily, weekly or shutdown work. It is important for owners and operators to prepare as much as possible to minimize potential project challenges. What is a plant Shutdown and Turnaround? A rigorous planning process is essential to capturing the cost savings and production benefits that excellent turnaround maintenance can provide. This is not where you should be concerned. It is critical to ensure full visibility of the turnaround planning to the plant restart, not leaving any activity without accountability. We recommend a clear stage-gate decision process, with a transparent process flow and criteria, like the one followed by a global player in the rubber and polymers industry. Before start-up, a final inspection will occur during which operations personnel, maintenance and specified third party participants will evaluate the readiness to open up again. With too much specification flexibility, a contractor may use cheaper, lesser quality parts to complete a project. The cutoff time should provide a reasonable time to plan and schedule so everyone is prepared when the job starts. This is when the initial planning is done and when you define things like time frame, budget, and the details about which assets will be impacted and which will be held out for another outage. When done well, turnaround maintenance may only be necessary every 4 to 6 years, depending on the specific installation. In Australia we call them maintenance shutdowns. In addition, plant turnarounds often require facilities to halt production. Certain parts may require longer lead times, so early engagement with vendors will help to ensure these parts will be available when needed. Owners and operators have a vested interest to make sure a turnaround goes smoothly. In the end, the startup was delayed because the engineering and maintenance schedules were not integrated. Part of being adequately prepared for a turnaround is the willingness of an operator to enlist the help of critical parts and service suppliers as early in the process as possible. What Is Turnaround Time? What Is Downtime? - Flyability Plant or refinery turnaround planning is a complex process that requires strategy and careful execution., Planning For a Successful Plant Turnaround. All elements of the process should be planned and assessed, and the key decision makers should then be able to make a call on whether or not this clear set of objectives are attainable. Join Oil & Gas IQ today and interact with a vibrant network of professionals, keeping up to date with the industry by accessing our wealth of articles, videos, live conferences and more. This paper has identified ten proven best practice solutions to strengthen turnaround maintenance planning. If you need help,Total Safety is ready! Not only are the tools and labour required for executing a turnaround extremely expensive, but the revenue lost through shutting down elements of production can amount to a significant portion of an annual budget. You want to avoid ordering certain parts one the project has started. It is mandatory to procure user consent prior to running these cookies on your website. June 6-8, 2023 The turnaround maintenance steering committee is typically comprised of the Plant Manager, Operations Manager, Maintenance Manager, HSE Manager, and Cost Controller. Whatever industry you're in oil and gas, refining, chemical processing, etc. But this proactive measure will save time, effort, and money in the long term. This paper distills findings from client experience and industry benchmarking, offering ten practical solutions for strengthening the turnaround maintenance planning process. A plant turnaround is defined as a major plant maintenance shutdown, typically involving the entire plant or multiple areas and lasts for several days (or if not properly planned and scheduled can last longer than expected). This can be a recipe for disaster. Please upgrade to Microsoft Edge, Firefox or Chrome for optimized website viewing. The terms plant turnaround and plant shutdown are used interchangeably when referring to a scheduled interruption of a plant's day-to-day operations to perform maintenance and a thorough inspection of the facility. Failing to strategize Shutdown/Turnarounds properly can also cause missed capital project opportunities. If specifications offer too much flexibility, contractors might use less expensive but lower-quality parts. If, for example, work orders are scheduled in the same place where a lock-out is taking place, then those work orders have to be re-assigned. Creating the schedule properly allows the organization to determine approximate downtime based on business requirements that have been decided upon. Leaders face an uncertain landscape. In many process industries (e.g., refining, petrochemicals, chemicals, power generation, etc. However, turnarounds also offer another key opportunity: a chance for plants to upgrade and improve their systems, which can mean higher reliability and performance.
Databricks Workspace Users, Articles W