Course Overview
This course provides in-depth knowledge and best practices for planning, executing, and closing plant shutdowns and turnarounds effectively. It focuses on aligning project management principles with maintenance execution, optimizing time and resources, managing risks, ensuring safety, and delivering successful outcomes with minimal downtime and cost overruns.
Course Objectives
By the end of this course, participants will be able to:
- Understand the full lifecycle of shutdown and turnaround projects.
- Develop detailed shutdown and turnaround plans, schedules, and budgets.
- Manage multidisciplinary teams and coordinate complex activities under tight timelines.
- Apply risk assessment and mitigation strategies.
- Ensure compliance with safety and regulatory requirements.
- Utilize modern tools and techniques for monitoring and controlling turnaround progress.
- Conduct post-turnaround reviews and implement lessons learned.
Who Should Attend
This course is suitable for:
- Shutdown and turnaround managers
- Maintenance and reliability engineers
- Project managers and planners
- Operations supervisors
- Safety and HSE personnel
- Procurement and logistics staff involved in shutdowns
Course Outline
Introduction to Shutdown and Turnaround Management
- Importance and impact of effective shutdowns
- Types and objectives of shutdowns and turnarounds
- Strategic vs. tactical turnaround planning
Planning Phase
- Scope definition and work breakdown structure (WBS)
- Developing schedules and resource plans
- Estimating costs and budgeting
- Risk assessment and contingency planning
Execution Preparation
- Mobilizing teams and contractors
- Material procurement and staging
- Job safety analysis (JSA) and permit-to-work systems
- Communication and coordination mechanisms
Execution and Control
- Kick-off and daily coordination meetings
- Managing scope changes and emergent work
- Performance monitoring (KPIs, progress tracking)
- Real-time problem solving and resource reallocation
Safety and Quality Assurance
- HSE management during high-risk activities
- Inspection and quality control procedures
- Regulatory and compliance requirements
Completion and Restart
- Commissioning and start-up readiness
- Final inspections and documentation
- Debriefing, post-mortem analysis, and reporting
- Capturing lessons learned and continuous improvement
Case Studies and Best Practices
- Success factors from industry turnarounds
- Common pitfalls and how to avoid them
- Application of digital tools and turnaround software