Shutdown and Turnaround Management
- Description
- Curriculum
Planning and managing shutdowns, turnarounds, and outages in process plant environments is a complex and high-stakes function. These events often attract intense top management attention due to their significant cost and operational impact. While this can lead to better resource availability, it may also result in excessive oversight. Like military operations, shutdowns should be led by experienced professionals. Poorly planned or executed turnarounds can result in budget overruns, schedule delays, and customer dissatisfaction. This program equips participants with core planning techniques, cost control strategies, and best practices essential for successful shutdown and turnaround execution.
Course Objectives
By the end of this program, participants will be able to:
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Manage all phases of shutdown and turnaround operations
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Develop scope of work and apply planning techniques
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Prepare detailed work packages for individual jobs
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Organize and manage workforce effectively
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Oversee shutdown production operations
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Optimize cost and contractor control
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Execute shutdowns under real-world constraints
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Apply HSE management systems and risk mitigation strategies
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Measure progress and report completion
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Prepare for safe and efficient startup
Training Methodology
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Booklets and handouts
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PowerPoint presentations
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Group discussions and case study practice
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Interactive workshops
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Instructional videos
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1
Day 1: Shutdown Fundamentals & Initial Planning-
Definitions and basics of shutdowns, turnarounds, and outages
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Differences between shutdowns, turnarounds, and projects
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Communication strategies and organizational structure
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Justifying shutdowns and developing master schedules
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Case study: Maintenance planning story
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Reasons and definitions for planning
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2
Day 2: Scope Development & Planning Techniques
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CMMS as a planning tool
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Identifying and prioritizing shutdown work
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Walkdown tours and future positioning
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Work validation, packaging, and individual job planning
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Case study: Scope of work preparation
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Project management concepts and boundaries
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Planning, monitoring, and control techniques
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CPM, PERT, and project management software
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3
Day 3: Risk, Logistics & Execution Essentials
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Hazard identification and risk management
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Equipment failure analysis
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Master schedule for Phase 2 planning
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Contractor integration and outsourcing strategy
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Budgeting and cost control
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Spare parts and logistics organization
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Case study: Oil/gas shutdown plan using MS Project
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Execution strategies and safety procedures
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Equipment isolation types and reporting
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Mechanical and electrical isolation sheets
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Safety lock-off systems
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4
Day 4: Execution Continuation & Completion
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Pressurizing and depressurizing vessel considerations
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Master schedule for Phase 3 execution
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KPI tracking and progress reporting
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Inspection follow-ups and modifications
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Completion, reporting, and close-out procedures
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5
Day 5: Startup Planning & Final Phases
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Master schedule for Phases 4 and 5
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Common startup challenges and solutions
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Staffing and material requirements
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General and detailed startup planning
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Machinery, static equipment, utility, and process startup operations
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Maintenance Managers, Engineers, Supervisors, and senior technicians
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Planning Managers, Engineers, Planners, and assistant planners
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Production Managers, Engineers, Supervisors, and senior operators
