Managing Efficient Shutdowns & Turnarounds

Introduction

This course covers the principles of automatic industrial control and the operation of the feedback loop to include proportional, integral and derivative control modes. Advanced concepts of cascade, ratio, and feedforward control are presented. Methods of controller tuning are presented and practiced. Improved control provides better productivity and efficiency. This course presents, step by step, practical, successful tuning methods that utilize closed-loop relationships and reaction curve analysis to tune feedback controllers in process industries. These methods can be easily understood and applied immediately to provide improved control of your processes. Also, this course explains the operation and application of advanced regulatory control methods: ratio, cascade, adaptive feedforward, override and deadtime control. Strategies are covered as well as mean to study process dynamics needed for implementation. You will learn how to tune advanced control systems to improve control of various types of processes. This will lead to a more efficient process operation.

Objectives

On completion of this course the participants will be able to:

• To enhance the company’s turnaround management capabilities, and to ensure a team approach in the planning and execution of plant shutdowns and turnarounds
• Provide a comprehensive understanding of effective turnaround management techniques and implementation
• Create awareness of planning methods and an integrated organizational approach in the execution of successful turnarounds
• Incorporate latest developments in turnaround planning and management techniques and emerging industry trends

Target Audience

• Shutdown or turnaround managers and coordinators
• Planning/scheduling and cost control staff
• Construction superintendents and supervisors
• Operations shutdown/outage coordinators
• Project engineers and contract administrators
• Participation from inspection, materials, safety and maintenance engineering is also encouraged

Instrumentation & Process Outline

The course covers the following topics:

Introduction to Shutdowns and Turnarounds

• Introduction to Shutdown and Turnaround Management
• The Shutdown Management Process
• Organization and Roles

Shutdown/Turnaround Preparation

• Plant Shutdown and Preparation for Maintenance
• Scope of Work Development and Work Breakdown Structures
• Preparation and Execution Issues
• Logistics, infrastructure and materials management

Shutdowns/Turnaround Planning Techniques

• Developing Shutdown and Turnaround Plans
• The Critical Path Planning Method
• “Short Cut” Planning Methods
• Developing the overall Shutdown Plan

Progress Monitoring and Control

• Progress Monitoring and Control
• Budgeting and Cost Control
• Earned Value, Earned Hours and Key Performance Indicators
• Finalization, Post-Audit and Improvement planning
• Contractors and Contractor Management
• Managing Safety

Safety, Quality and Risk Management

• Managing Safety and Quality
• Risk Management
• Overview of Computerized Tools
• Conclusion