1 / 1

Prepare

Turnaround Preparation, Planning, Execution and Review Process. Phase 1 Review Long Range Business Plan & Schedule. Phase 2 Prepare the Turnaround Criteria & Deliverables. Phase 3 Develop the Turnaround Work Scope. Phase 4 Complete All Turnaround Planning. Phase 5

derek-decker
Télécharger la présentation

Prepare

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Turnaround Preparation, Planning, Execution and Review Process Phase 1 Review Long Range Business Plan & Schedule Phase 2 Prepare the Turnaround Criteria & Deliverables Phase 3 Develop the Turnaround Work Scope Phase 4 Complete All Turnaround Planning Phase 5 Complete Pre-Turnaround Work Phase 6 Execute the Turnaround Phase 7 Complete Post Turnaround Documentation & Review No No No No No No No • Endorser: • President, Refining • Decision Executive: • Vice President, Refinery Manager • Decision Review Board: • Maintenance Manager, Operations Director, Planning & Economics Director • Endorser: • Refinery Manager • Decision Executive: • Operations Director • Decision Review Board: • Complex Manager, Turnaround Manager, Engineering • Director, Planning & Economics Director, • Reliability Manager, Project Engineering Manager • Endorser: • Operations Director • Decision Executive: • Operating Complex Manager • Decision Review Board: • Planning Engineer, Turnaround Manager, Project • Engineering Manager, Reliability Manager • Endorser: • Operations Director • Decision Executive: • Operating Complex Manager • Decision Review Board: • Planning Engineer, Turnaround Manager, Project • Engineering Manager, Reliability Manager • Endorser: • Operations Director • Decision Executive: • Turnaround Project Manager • Decision Review Board: • Turnaround Core Team • Endorser: • Operations Director • Decision Executive: • Turnaround Project Manager • Decision Review Board: • Turnaround Core Team • Endorser: • Operations Director • Decision Executive: • Operations Complex Manager • Decision Review Board: • Maintenance Director, Planning Engineer, Turnaround • Manager, Project Engineering Manager, • Reliability Manager Are the deliverables complete and adequate? Are resources adequate? Are the plans competitive? Is the execution plan complete? Will plan meet short range plan? Is plant and off-plot ready? Will scope meet long range plan? Turnaround CloseoutComplete? From Phase 7 Is plant on-test? Deliverables met? Yes Yes Yes Yes Yes Yes Yes Prepare Review Plan Execute • Frozen work list • Planning & labor forecast • Prelim. execution plan • Planning schedule • Procurement plan • Audit report • Core Team • Planning schedule • Opportunity & framing document • Planning and labor forecast • Stakeholder communication plan • Execute as planned • Schedule reports • Cost reports • Lessons learned • Pre Startup Safety Review • Final execution plan • WOs, Lists, procedures • Final AFE • Audit Report • Training plan • Schedule & cost reports • Field mobilization • Pre-work • Clean plant • Final reports • Plan for next Turnaround • Audit report • Long Range Turnaround Schedules • Budgets • Short range plan Return to Phase 1 Start Here • Team Leader: Planning & Economics Director • Team: • Turnaround Manager • Project Engineering Manager • Operations Director • Reliability Manager • Team Leader: Turnaround Project Manager • Team: • Operating Representative • Reliability Representative, Inspection • Design Engineer • Process Engineer • Capital Project Manager • Maintenance Representative • Team Leader: Turnaround Project Manager • Team: • Operating Representative • Reliability Representative, Inspection • Designs Engineer • Process Engineer • Capital Project Representative • Maintenance Representative • Contractor Representative • Team Leader: Turnaround Project Manager • Team: • Operating Representative • Reliability Representative , Inspection • Designs & Process Engineer (1 each) • Capital Project Representative • Maintenance Representative • Contractor Representative • Team Leaders: Turnaround Operations Coordinator & Maintenance Supervisor • Team: • Operators • Mechanics • Engineers • Inspectors • Contractors • Team Leaders: Maintenance Supervisor & Turnaround Operations Coordinator • Team: • Operators • Mechanics • Engineers • Inspectors • Contractors • Team Leader: Turnaround Project Manager • Team: • Operating Representative • Reliability Representative, Inspection • Designs Engineer • Process Engineer • Capital Project Representative • Maintenance Representative • DELIVERABLES & DOCUMENTS • Short Range Turnaround Schedule • Long Range Turnaround Schedule • Short and Long Range Budgets (Phase 1 Estimates) • FOCUS AREAS • Determine local and national mechanical labor force limits • Review policies and regulations impacting turnaround requirements • API/Boiler Codes/Laws & Regulations / RBI • Review Unit Performance vs. Benchmarks • Intensive Process Review • Yield / Energy / Reliability / OPEX • Turnaround interval / Cost /Duration • Interval Limits • Determine Capital Requirements • Environmental Compliance • Market Needs • Technology Gaps • Reliability Improvements • Plan to Minimize Lost Profit Opportunities • Value of Downtime • De – cluster the Turnarounds • Coordination with San Antonio • Market Conditions and Changes • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Solomon Study • Business Plan • API / Boiler Codes / Company Specs • Plant Inspection Plans • Intensive Process Review • Lessons learned / Final Report from Last Turnaround • Turnaround Process Checklist • Long Range Capital Plans • APN Tool Set • TIMING – PHASE 1 • On-going, part of annual planning cycle • DELIVERABLES & DOCUMENTS • Core Team • Turnaround Philosophy • List of Stakeholders • Stakeholder Communication Plan • Turnaround Planning Milestone Schedule • Preliminary Planning-Resource Forecast • Preliminary AFE • FOCUS AREAS • Dedicate resources • Define value of plant downtime • Determine Solomon targets • Define work list criteria • Review of Turnaround history & lessons learned • Define interval and limits • Complete On-Stream-Inspection • Perform RBI study • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Change management process • Turnaround Planning Process Overview • Define roles & responsibilities • Input checklist • Solomon RAM Tables • Inspection Records • Computerized Maintenance Management System • Long Range Turnaround & Capital Plans • Incidents & Worst Actor Equipment • RBI Process • Turnaround Process Checklist • Lessons learned / Final Report from Last Turnaround • APN Tool Set • TIMING, PHASE 2 COMPLETED • • 24 - 15 Months Prior to Turnaround • DELIVERABLES & DOCUMENTS • Frozen Work List • Planning-Resource Forecast • Preliminary Execution Plan • Contracting Strategy • Labor Loading Estimate • Safety Plan • Environmental Plan • Facilities Plan • Operating Procedures • Phase 3 Estimate and Schedule • Procurement Plan • Planning Schedule • Peer Review / Scope Review Report • FOCUS AREAS • Finalize all inputs • APN review data • On stream inspections • Incidents • Worst actors • Inspection History • Maintenance Backlog • RBI Study • Safety / Environmental • Capital Plan • Turnaround History • Eliminate all non-turnaround work • Evaluate key plant reliability concerns • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Turnaround philosophy document and criteria to Screen Potential Work Items • Peer Review / Scope Review • Self review or use APN Tools • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PHASE 3 COMPLETED • 12 Months Prior to Turnaround • DELIVERABLES& DOCUMENTS • Post Turnaround cleanup of unit and staging areas • Final Report / Metrics • Starting place for next Turnaround • Preliminary repair and replace work list • Action items and owners • Meeting schedule for next Turnaround • Audit Report • FOCUS AREAS • Demobilize contractors • Resolve excess materials • Communicate lessons learned • Publish recommendations for future Turnarounds • Update inspection & repair history • Update Turnaround history database • Complete post-Turnaround MOC requirements • Complete APN review • Stakeholder communications • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • RBI process • Peer Review / Results and Lessons Learned • APN Review • Scheduling & planning software P3 • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PERFORM PHASE 7 REVIEW • • 3 Month Post Turnaround • DELIVERABLES & DOCUMENTS • All Work Instructions, Lists and Procedures • Final Execution Plan • Organization Chart • Contracting Plan • Inspection Plan (1st Third) • Safety Plan • Environmental Plan • Facilities Plan • Operating Procedures • Tank and Line Plan • Critical-Path, Manpower-Loaded & Leveled Schedule with operations • Completed Phase 4 Estimate • Risk Assessment & Mitigation/Contingency plan • Communication Plan • Final Approved AFE • APN or Peer Review Report • FOCUS AREAS • Complete shutdown & cleanup plan • Complete commissioning and startup plan • Complete work orders, lists and procedures • Constructability reviews • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Schedule Software • Addition Work Control Process • Work Order, List and Procedure Completion Rate • Peer Review / Critical Path Challenge • Self- turnaround review or APN Tools • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PHASE 4 COMPLETED • 4 Months Prior to Turnaround • DELIVERABLES & DOCUMENTS • Training plan • Field mobilization and logistics plan • All pre-work complete • Schedule and cost reports ready • FOCUS AREAS • Train operators, mechanics, supervisors • Work scope • Procedures • Train for contractors • Safety • Maintenance specifications • Mobilize execution team • Set up safety, health, environmental requirements • Complete MOC requirements • Install temporary connections for cleanup • Hang all tags • Stage tools, blinds and materials • Begin cost tracking and reporting • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Turnaround execution plan • Scheduling & planning software - P3 • Additional Work Control Process • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PHASE 5 COMPLETED • • Feed pulled • DELIVERABLES & DOCUMENTS • Execute turnaround per plan and schedule • Pre start up safety review complete • Daily schedule and cost reports • Lessons learned captured • FOCUS AREAS • Conduct safety audits • Hold daily Turnaround meetings • Monitor schedule float and critical path • Prepare plan for next shift • Finish inspection in 1st third of turnaround • Monitor cost tracking and reporting • Review and document MOCs • Review and process additional work • Document all repairs • Manage QA / QC • Manage inter-plant coordination & communication • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Quick MOC process • Turnaround Execution Plan • Scheduling & planning software • Additional Work Control Process • Risk Mitigation/Contingency Plan • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PHASE 6 COMPLETE • Feed in

More Related