Turnaround Management

MAI/TURNAROUNDGB

Who should attend?

  • This course aims to bring elements pertaining to the management specificities of major turnarounds, their organization, the concerns and processes implemented during this period of life of a unit or an industrial site.
Audience :
  • Personnel involved in the preparation or completion of a major turnaround.

Level : Proficiency

Course Content

  • ROLES & REQUIREMENTS OF A TURNAROUND

      • Frequency and duration of turnarounds, running rate of units, economic impact of a turnaround.
      • Elements of maintenance policy.
      • Turnaround constraints: legal obligations, safety, technical and economic reasons:
      • Pressure equipment operating constraints.
      • Notion of lifetime cost of large machines.
      • Maintenance works and new works – modifications – carried out during a turnaround.
      • Compliance with the cost, deadlines, quality, environment and safety.
  • PREPARATION OF A TURNAROUND

      • Turnaround preparation team, organization chart, turnaround manager, definition of tasks and processes.
      • Collection, analysis and preparation of work: written compilation of jobs, job process reviews.
      • Equipment reservation, cost estimate and budget.
      • Preparation of the logistics. Preparation of the specific spare parts and tools.
      • Planning. Identification of the critical operations.
      • Selection of trades, markets, integration of quality and safety in the call for tenders.
      • Scope changes and closure of job requests (scope freeze).
      • Effluent and waste management, safety and prevention, quality, QHSE manual.
  • SCHEDULING & DELAYS CONTROL

      • Concerns of the turnaround manager (pilotage, overview, key dates).
      • Planning methods PERT, GANTT:
      • Tracking task levels.
      • Calculation of task dates, at the earliest, at the latest.
      • Optimize work programs (work in parallel, avoid wasting time...).
      • Concept of total and free margins. Identification of the critical path. Exercises.
  • INSPECTION OF PRESSURE EQUIPMENT

      • Effect of pressure and temperature.
      • Metals, alloys and potential risks.
      • Process fluid aggressiveness.
      • Pressure equipment design and manufacturing.
      • Legal orders: regulations on pressure equipment operation.
  • OUTSOURCING & SUBCONTRACTING

      • Definition, origins, interests, risks.
      • Problems due to cascading subcontracting.
      • Purpose, conditions for efficiency. Why outsourcing? Which abilities to be kept? How to keep control?
      • Different types of contracts.
  • WORKS EXECUTION, CONTROLS & AUDITS

      • General principles of the works activity.
      • Preliminary activities: scaffolding, worksite installation, drawings and documents.
      • Equipment preparation: preparation before work, blinding, identification.
      • Permit issuance, management of recommendations, inspection.
      • Follow-up of works progress: supervisors’ reporting to the planning manager, cost control.
      • Worksite audits: communication and observation techniques, report and recommendations.
      • Equipment closure and leak test.
      • Unit preparation to re-startup: operation review, start-up acceptance, assistance to start-up.
      • Commissioning organization.
      • Production start-up organization and procedure.
  • SAFETY IN WORKS

      • Implementation of a HSE management system.
      • HSE management of turnover and construction activities.
      • Technical and safety worksite audits.
      • Management of change.
  • END OF WORKS & TERMINATION OF TURNAROUND

      • Detail review, final acceptance.
      • Turnaround report: inspection report, operation report…
      • Turnaround manager’s report.
      • Use of performance indicators and sharing of feedback.

Learning Objectives

  • Upon completion of the course, participants will be able to:
  • understand what motivates or dictates the planning of turnarounds, know the terminology on pressure equipment regulations,
  • actively take part in the management and supervision of a turnaround,
  • have a better approach to the regulatory and legal framework of outsourcing,
  • have a broader understanding of the hazards and risks (products, works) and the associated prevention measures,
  • carry out inspections and site audits.

Ways & Means

  • Applications and case studies illustrating turnaround situations and stages.
  • Active pedagogy based on participants' experiences.