what is a turnaround in a plant

A cutoff date is defined as the last day that any new work can be added to the shutdown including projects, maintenance, installations, etc. Usually, operations need to stop for maintenance, to replace equipment, to upgrade energy resources or to maintain regulatory compliance. In USA they call them maintenance turnarounds. That said, a lot of the relevant data is often missing, meaning it cannot be leveraged to develop a plan. Even with those factors addressed, its still difficult to foresee certain variables, such as the exact number of parts needed during a certain turnaround. Tracking and planning turnaround maintenance shutdowns with a 10-year, all-plant window yields insights into optimization opportunities, inefficient patterns, and best practices. A related term is Shutdowns, Turnarounds, and Outages[1][2][3] sometimes written as Turnarounds, Shutdowns, and Outages (TSO).[4]. Turnarounds often involve hundreds of workers from different companies, making it difficult to maintain consistent levels of installation knowledge. Best practice is to have at least two months cutoff time for an annual shutdown or turnaround. Unlike shutdowns, outages dont occur in an effort to protect equipment or personnel. Best practices. This is the lengthiest phase of the turnaround, taking anywhere from 6-18 months. For example, many facilities have zero equipment operating parameters showing employees how well or poorly key equipment is operating. Turnaround maintenance management encompasses first planning for the shutdown, then procurement of equipment, materials and expertise, and finally execution of the event. As with any major project, variables and contingencies are inevitable, so anticipating them is another way owners can improve overall turnaround effectiveness. 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.) unsubscribe at any time. A turnaround, sometimes called a TAR, is a regular, planned procedure that takes part or all of an oil refinery (or other industrial plants) offline to allow personnel to inspect and renovate the facilities. What Is Turnaround Time? What Is Downtime? - Flyability What is a Plant Turnaround? Challenges and Ensuring Compliance. 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. We respect your privacy, by clicking 'Subscribe' you will receive our e-newsletter, including information on Podcasts, Webinars, event discounts, The turnaround organization encompasses all personnel responsible for the planning, scheduling, management and execution of the turnaround. Some questions to ask in considering your current turnaround maintenance organization structure. Sound planning is essential to turnaround maintenance (TAM) success, encompassing process design and adherence, people and organization, governance, metrics, and tools. Anticipating these variables is a way to improve overall turnaround effectiveness. Complete and share turnaround maintenance vendor evaluations and remove any assets that must be disposed of from the plant. This process can be one of the biggest challenges that asset owners face. During a turnaround or shutdown, speed is of the essence. Crucially, all shutdowns and turnarounds should be well-defined, planned realistically, and executed efficiently. Modify budget approval to ensure the budgetary estimate is secured at least one year before the actual turnaround maintenance dates based on a 10-year turnaround maintenance schedule. Plants are long-term assets, designed to operate for 10, 20, 30 years. Read about our best practices for overcoming these challenges. Shutdown schedule compliance to learn more. Careers With IQPC| The 4 Stage for an Effective STO (Shutdown, Turnaround & Outages), Turnaround Cost Management for STOs: Improve performance of your TA with integrated software Cleopatra Enterprise, 4 Things You Can Do to Gain Quick Maintenance Wins, The #1 Problem Facing Turnarounds, Shutdowns and Outages, Practical Management for Plant Turnarounds, https://en.wikipedia.org/w/index.php?title=Turnaround_(refining)&oldid=1037853676, Creative Commons Attribution-ShareAlike License 3.0, This page was last edited on 9 August 2021, at 03:01. Formalize champion and challenger roles, perhaps involving external third-party experts, to increase rigor in the turnaround maintenance planning and scope challenge processes. This category only includes cookies that ensures basic functionalities and security features of the website. Talk to a Total Safety expert today at 888-328-6825! Get the details on Maintenance Connection's industry-leading, data-backed software solutions. Refineries and chemical plants do not undertake plant turnarounds lightly due to their inherent complexity. Best practice optimizes turnaround maintenance in high-margin plants for the duration and low margin plants for cost. Are key functional leads on the turnaround maintenance project team 100% dedicated to the planning effort? The success of any turnaround project is the result of thorough strategic planning and the careful execution of that plan. The purpose of the Planning Phase in Shutdown/Turnaround Optimization is to plan the jobs from the worklist created in Phase 2, the start-up and shutdown activities, and the safety and environmental procedures. The focus during the Scheduling Phase is on integrating schedules, the critical path, shutdown execution management, logistics, and organizing resources (including contract management). Outages are the third and most-often overlooked type of shutdown activity. 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. Heavy manufacturing and processing sectors confront structural or temporary drops in demand and constraints in their supply chains. The turnaround maintenance team tracks progress against the KPIs and reports regularly to the steering committee. Staying within budget including the need to account for everyones time and energies: a sloppy budget will cause a sloppy TAR, Coordination of logistics including the monitoring of external workers who may be unfamiliar with processes and the STO site, and. This is usually done by the Shutdown Manager. Evaluation including the collection of data metrics and the ultimate goal of improving business performance. Those delays lead to significant revenue reduction as affected plants cannot get started quickly or efficiently. 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. Taking all that into account, the following seven tips will help owners and operators ensure effective turnaround management, enabling them to save significant time and money not to mention headaches. Charlotte-based Glatfelter Corp. (NYSE: GLT) said today it will close a Germany facility as part of its . For a manufacturing plant, a halt in production is devastating. You also have the option to opt-out of these cookies. Let us take a deeper look into specific turnaround phases and how they can be optimized. A base analysis of a refinery will give an overview of the scope and duration of any shutdowns and turnaround needed. review Fixed Time Maintenance (FTM) work. is ready! How to Plan for a Successful Plant Turnaround - Total Safety It can be difficult to make sure that people are executing those procedures correctly or that they have been properly trained to do so. Why? In many cases, minor shutdowns can have a bigger impact on lost production. What are shutdowns and turnarounds? - Oil & Gas IQ And, as you know, turnarounds aren't business as usual. To simplify this discussion, we have defined five different phases of a turnaround process, discussing the particulars of each phase as well as typical challenges that tend to arise along the way. Rather, the vendor will customize the panels to the plants specifications and optimize the components inside for accuracy and safety, simplifying future maintenance and repair needs while also enhancing the ability of owners to draw proper samples more easily (see Figure 1). Owners must sign off on system adjustments well before a turnaround event. Additionally, there can be coordination concerns in the field, including high waiting times. Online. Estimated turnaround maintenance costs can be included in the prior years budget based on historical spending and approved for use whenever necessary. Typically led by an ex-senior plant manager with operations or maintenance experience in a similar facility, the teams members include senior subject matter experts and operations, maintenance, and reliability professionals from the companys other plants. For most of 2020, global specialty chemical production, for example, remained at least 8% below previous levels. Owners and operators have a vested interest to make sure a turnaround goes smoothly. It is unacceptable. 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.) The goal of the six phases is to drive unscheduled downtime to zero as well as increasing Overall Production Efficiency (OPE) to create the opportunity to increase output. If the entire plant needs to be maintenanced, turnaround time will refer . Headcount reductions have created gaps in knowledge and continuity. 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. Strain is increased on other suppliers to meet demands, and turnarounds which become shutdowns can be catastrophic for supply at a regional level. This paper distills findings from client experience and industry benchmarking, offering ten practical solutions for strengthening the turnaround maintenance planning process. In this blog, we will outline the five phases of a turnaround process and the challenges associated with each phase. 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. Language links are at the top of the page across from the title. The importance of turnaround maintenance to plant safety and uptime has insulated it to some extent from normal reengineering and budgeting efforts. 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. During a normal turnaround or shutdown, companies are looking to return their systems to their actual original working condition. Sometimes waiting for a single part can cause significant progress delays. Instead, we recommend a structured process at three key points in time, before restarting the plant; within 15 to 30 days of the restart; and within 3 months after the restart. During this time, production must come to a complete stop. Better understand the built environment with visual, at-a-glance info. As such, their predictable cycles of investment and deterioration dont mesh easily with companies typical 2 to 5-year planning horizons. Its common for operations to stop for maintenance, cleaning, equipment replacement, repair, upgrade resources, or to maintain regulatory compliance. READ: The Complete Guide to Shutdowns and Turnarounds. 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. How long did a work order take? Your organization must identify the business requirements and drivers. This phase is critical to the determining the time required for the plant production to be offline. Moving components and expertise across national borders is fraught with delay and difficulty. At the end of the Strategic Phase (if the steps are followed), you will have increased run time, decreased frequency of shutdowns, optimized outage duration, and good coordination with the overall business plan. you'll likely be involved in a turnaround at your plant. With this range established, the head of the steering committee approves a go-ahead scenario. It is mandatory to procure user consent prior to running these cookies on your website. Failing to strategize Shutdown/Turnarounds properly can also cause missed capital project opportunities. Weve developed effective and efficient services that can help improve safety and drive project efficiency. The cutoff time should provide a reasonable time to plan and schedule so everyone is prepared when the job starts. 12:30 PM - 01:30 PM GMT. Shutdowns, Turnarounds, and Outages (STO) are commonly used terms, often interchangeably, to describe a planned or unplanned period of time in which a plant/facility, unit, or piece of equipment is out of service. 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. Scoping can generally happen based on experience or expectation. With your turnaround project, plan at least 8-12 months in advance before the shutdown or turnaround occurs. At its peak, a turnaround maintenance event can mobilize up to a thousand people between internal resources and external. So, as you can see, the Work list Review Phase can improve the duration of your shutdown/turnarounds by ensuring the work is valid for the next shutdown. When weve been at client sites, we often hear that Shutdown/Turnarounds arent managed well. Does the mere word make you shudder? Complete the evacuation, cleaning, and housekeeping procedures to allow uninterrupted operations post-start. Training solutions to meet the needs of every organization. A sound turnaround strategy helps reduce downtime, improves safety, and reduces costs while enhancing business process optimization and mitigating risk. When was the last time you reviewed the work being done during your shutdown/turnarounds? It is a common mistake for different departments working on the same equipment at the same time because they are not operating under an integrated schedule. 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. Finally, this overarching turnaround maintenance schedule gives companies a way to anticipate and manage interdependencies. And it may be useful to employ an external party to tightly manage scope challenge and work order detailing, minimizing future disruptions to the working plan. Crucially, this approach allows companies to better attract and manage service providers. Quality control over parts and equipment is essential to executing a successful turnaround. These meetings should be included in the countdown schedule so that the date and time is designated for when a decision needs to be made about what to include in the shutdown. A turnaround which is sometimes referred to as a TAR is a highly-expensive planned period of regeneration in a plant or refinery. We have the people, programs, and experience to provide the support you need during crucial turnaround and shutdown periods. Challengers may be experts from elsewhere in the company or from outside. A turnaround can often entail the use of hundreds of technicians from multiple vendors, all aiming to finish important maintenance, revamping, and renewal projects either on specific systems or across entire plants at once. An industrial plant turnaround is a planned shutdown of a facility. In the six months following this scope challenge then freeze, any additional work requests are subject to intense evaluation. Today, thanks to advances in equipment reliability and maintenance programs, turnarounds happen less often than before. Understanding and defining the scope of the turnaround is foundational to its success. The complexity of major fluid systems means specialized parts and components constructed from specific alloys will be needed for various processes. By Jenna Martin. 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. Because they are cyclical, these outages should be dealt with as holistically as possible, and not treated simply as a break in normal proceedings. When contracting work, identify which work will be outsourced, consolidate the number of contractors, identify contractor coordination, decide on the selection criteria for contractors and verify qualifications, and evaluate the contract work at the end of the project. 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. Good planning is often the key to success, and with shutdowns and turnarounds, it is no less true. is taken offstream for an extended period for revamp and/or renewal. Once you have all of this information delineated, it can be used for approval and distribution of the plan throughout the organization The primary challenge? 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. This final review phase is when you answer these questions and hopefully streamline your processes for the future. Developing a countdown schedule is crucial because it gives the whole organization a direction on what to prepare and when. The primary issue here is that there are new procedures that need to be executed for the first time, and you are dealing with a very uncertain situation with unfamiliar procedures and an influx of data. How often did you reschedule work orders? To-date most companies have not prioritized turnaround maintenance in their cost reduction efforts. These multi-year arrangements include external contracts for core manpower services such as scaffolding, welding, cleaning, and hydro- jetting. Cyber security for critical infrastructure [podcast], Structural integrity management in oil and gas. The more time you spend preparing, the better off you will be when it comes times to execute. Leaders face an uncertain landscape. As a result, a poorly managed turnaround can be costly for plant managers. You can Turnaround maintenance organization structure aims to solve two problems. There are a few key areas to focus on when proceeding with an STO. Using general maintenance people, while possible, is inefficient and may also create risk. The terms Plant Turnaround, Plant Shutdown, Plant Outage imply a lengthy stoppage of a whole operation to do maintenance. Before restarting the plant, ensure all critical jobs are completed, as well as pre- startup safety reviews. May 31, 2023. 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. 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. A turnaround is a scheduled stoppage of part or all of a plant's day-to-day operations. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. In fact, it is not unusual for turnarounds to be a significant part of the plants annual maintenance budget. Effective shutdown management is critical, This article provides guidelines on the selection and structure of the codes and categories that CMMS Software work order systems use to filter and sort backlogs of work. This phase begins immediately once the plant is shut down, and it involves the execution of work orders, contractor mobilization and mobilization of workers in the field. Today, we work closely with clients to embrace a transformational approach aimed at benefiting all stakeholdersempowering organizations to grow, build sustainable competitive advantage, and drive positive societal impact. All major oil and gas companies are committed to developing both their scientific and service knowledge, ensuring that shutdowns prioritize what is best from a technical and customer point of view. Replacing traditional grab sampling elements in a system with pre-engineered and assembled grab sampling panels is just one example of a potential system improvement. 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. Update all impacted Standard Operating Procedures (SOPs). Explore the 5 phases of a plant turnaround process and its challenges in order to avoid the pitfalls and make successful upgrades and repairs. They are cash guzzlers, influencing 10% to 20% of annual non-feedstock spend, consuming up to 50% of plants total annual maintenance budget, and with an additional 5% to 10% impact on facility uptime and quality. Boston Consulting Group partners with leaders in business and society to tackle their most important challenges and capture their greatest opportunities. With too much specification flexibility, a contractor may use cheaper, lesser quality parts to complete a project. Unlike turnarounds, shutdowns are not always planned. This may include personalization of content and ads, and traffic analytics. Turnaround time at an industrial plant is the amount of time needed to shut down a specific asset or an entire operation in order to conduct maintenance or some other process. With any turnaround project, certain obstacles or circumstances beyond plan are inevitable. As summarized in Figure 2, they span all five components of turnaround maintenance planning and address the common challenges. So, its important to have a variety of parts, tools, and equipment on hand before the project begins. Here. 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. Plan for the unseen. What is a Turnaround in the Oil and Gas Industry? In short, it is all the work that needs to be done to ensure an effective turnaround execution. It is mandatory to procure user consent prior to running these cookies on your website. Meet the customers who use Maintenance Connection software to improve their business operations. What You Need to Know About Industrial Shutdowns & Turnarounds This is a high priority. Sign up now and get FREE access to our extensive library of reports, infographics, whitepapers, webinars and online events from the worlds foremost thought leaders. Plant turnaround or plant shutdown is both an inescapable reality and a common occurrence in many asset-heavy industries. Turnarounds & Shutdowns | Inspectioneering Through experience with major clients and expert best practices benchmarking, BCG has developed a holistic, practical approach to helping companies improve efficiency, effectiveness, and reliability in their turn- around maintenance efforts. Turnarounds are expensive - both in terms of lost production while the process unit is offline and in terms of direct costs for the labour, tools, heavy equipment and materials used to execute the project. In Australia we call them maintenance shutdowns. We have the people, programs, and experience to provide the support you need during crucial turnaround and shutdown periods. A rigorous planning process is essential to capturing the cost savings and production benefits that excellent turnaround maintenance can provide. Almost 50% of work-related accidents in manufacturing plants occur during plant maintenance outages. Such parts typically require longer lead times, so early engagement of authorized vendors will help to ensure these highly engineered parts will be available when needed. The goal is that each asset must be as good, if not better, than when the turnaround started. Extending turnaround activities may result in fuel shortages, price increases, or both. Download Total Safetys Safety Moments Mobile App. -- and engineering data may need to be updated by multiple contractors. Equipment in need of maintenance, repair, or replacement should all be identified in advance, and the necessary resources, equipment, and personnel prepared on the back of this. In addition, plant turnarounds often require facilities to halt production. Within 15 to 30 days of the restart, ensure all areas impacted by the turnaround maintenance are operating satisfactorily. The unit must be shut down to work on the control valve and there may also be a problem with the check valve. This makes it nearly impossible to build a cross-functional understanding of the work to be done and the proper sequence needed to ensure safety, eliminate rework and drive true critical paths through your project plans. In many major companies, specialized teams move from facility to facility, acquiring knowledge and experience with every additional turnaround maintenance they carry out. Improving systems does not happen by chance. It is easy to get stressed about making mistakes and become disorganized. What would your organization look like if over 80% of your work orders did not satisfy requirements? Optimize the turnaround maintenance organizational structure, roles, and people. These cookies do not store any personal information. Cutting purchasing spend and shutdown time can yield substantial savings as can increasing the time between necessary turnaround maintenance events. This example is from IDCONs Maintenance Planning and Scheduling Book. If there is no plan on how to meet market and seasonal demands on the products, production wont be able to meet demand and it will interrupt the high season and customers deliveries wont be made. True, this process does take time and further strategic planning to execute such improvements. What is scheduling exactly? 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. They are exclusively dedicated to a given turnaround maintenance for the entire duration of its planning and execution. We use cookies and other tracking technologies to analyze and improve your user experience. Difference in plant turnaround, maintenance shutdown, maintenance outage The company may use more of its standing global contracts for activities such as scaffolding and equipment rentals to optimize for cost. During your initial scoping, then, it is important to not only keep the 30,000-foot view, but also to make sure that your zoomed in view is clear and that you understand what needs to be done for each individual pipe, valve or machine. In industries where plants operate continuously like oil and gas, petrochemical, pulp and paper, or steel refineries turnaround maintenances are instrumental in identifying and mitigating the risks associated with wear and tear on equipment and connections.
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