Introduction

Shutdown, Outage and Turnaround (STO) Management is an essential activity in process industry. It plays an important role in maintaining consistent productive capacity. It is a major project that requires sound planning, execution, and control. There is a need for a structured approach and guidelines for initiating, planning, executing, and terminating shutdown.

This Advanced Shutdown and Turnaround Management training course seeks to provide you with skills such as measuring success of a shutdown project, advanced methods for setting priorities for shutdown planning and execution based on multiple criteria, and knowledge about advanced project management techniques.

Goals

Participants will learn:

• Ability to set priorities and allocate resources with constraint of budget and time.
• Perform analysis based on set key performance indicators with respect to shutdowns.
• Assess role of shutdown planning and execution within computerized maintenance management systems.
• Learn from case studies of successful and unsuccessful shutdown and turnaround projects.

TRAINING OBJECTIVES

• Prepare shutdown works list.
• Prepare shutdown budget.
• Plan shutdown dates and duration.
• Prepare shutdown scope of work.
• Plan shutdown activities.
• Select and build shutdown management team.
• Schedule shutdown activities.
• Supervise shutdown activities execution.
• Conduct shutdown reporting.
• Perform Risk Management for Shutdown.

Training Methodology

Facilitated by an experienced maintenance specialist, our program will be conducted as a highly interactive work session (as opposed to lectures), encouraging participants to share their own experiences and apply the program material to real-life situations. Each delegate will receive an extensive reference manual, as well as case studies, while worked out solutions will be handed out to the delegates on conclusion of group discussions.

TRAINING SUMMARY

To enhance course participants’ competencies related to planning, preparation and execution of offshore plants overhaul shutdowns.

Target Groups

• Maintenance and Reliability Managers involved in Shutdown Planning.
• Maintenance and Reliability Supervisors.
• Personnel designated as planners or identified to become planners.
• Team leaders from each Maintenance craft.
• Key Operations Supervisors.
• Materials Management Managers/Supervisors.
• CMMS Administrator or key users.
• Key Maintenance support assistants.
• Other stakeholders in the Work Planning Function.

Program Content

Day 1 - An Overview of Maintenance Practice and Introduction to Maintenance (Asset) Management & Shutdown

• Definitions of key terms – Basics of Shutdowns, Turnaround and Outages.
• Size of Shutdown.
• How to Measure the Success of a Shutdown?
• KPI (Key Performance Indicators).
• What is the Basic Difference between Traditional Project Management and a Typical Shutdown?
• Types of Maintenance - Reactive, and Proactive.
• Maintenance in the Business Process.
• Evolution in Maintenance Management.
• The Principle of Prioritization.

Risk Management: The Concept of Best and Worst Practice

• Why Systems Fail?
• Cases of Failures from Different Industries.
• Failure Analysis and Technical Causes of Failures.
• Generic Lessons Learned and Improvements.

Day 2 - Overview of Shutdown Planning Phases

• Definitions.
• Business Perspective
• Maintenance Issues.
• Engineering Context.
• Technical Issues.
• Shutdown Phases
• Timeliness and Audits

Structured approach for managing Shutdown Planning

• Initiation.
• Planning.
• Execution.
• Termination.

Day 3 - Project Planning & Scheduling

• Importance of Planning and Scheduling.
• Project Management Techniques for Optimization.
• Network Analysis.
• Critical Path Analysis
• Optimization of PM Schedules.
• Optimum Resource Allocation.
• Resource leveling.
• Resource smoothing.
• Resource Planning.
• Functions to look for in Your PM Software.

Day 4 - Preparation for Shutdown

• Plan shutdown dates and duration.
• Prepare shutdown scope of work.
• Plan shutdown activities.
• Select and build shutdown management team.
• Schedule shutdown activities.
• Supervise shutdown activities execution.
• Shutdown reporting.

Day 5 - Decision Analysis for Optimization of Maintenance Activities

• How to get the most of your CMMS?
• Benefits that can result from CMMS.
• Optimum Decisions for Maintenance Policies.
• Unmet needs in Responsive Maintenance.
• Key Features of Next Generation Maintenance Systems.
• Risk Matrix of Shutdowns and Response.
• How to transform Data to Decisions.
• Examples of Approaches and Case Studies.