Aligning Priorities to Yield Successful Turnarounds

By Marcus Evans May 06, 2013

Key factors and fundamentals of achieving timely turnarounds, including tips in planning, executing, and analyzing performance.
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Refinery and Petrochemical turnarounds are very complex, costly, and dangerous

events. Not only do they take years to properly plan, but they also require 100% focus during execution to make it a successful effort. The tips below highlight key areas that every organization should focus on to best leverage their assets:

FORTIFYNG THE FUNDAMENTALS TO FURTHER A SOLID FOUNDATION

Envision a More Timely and CostEfficient Turnaround

Develop steer team vision to encourage cohesive efforts Interact effectively as a team to develop shared priorities Prioritize work from the top down to plan more practically Reshape and distribute doctrine to reinforce and promote corresponding action Promote leadership and plant consistency

Improve Projection of Scope to Achieve More Acute Planning

Comprehend the impacts of early

planning on outcome Ramp up schedules to minimize work scope Integrate detailed projectschedules to clarify projects Detail maintenance activities to reduce turnaround work Reduce scope through more exacting prioritization of work

Develop Metrics to Improve Budget Estimates for Greater Cost-Efficiency

Review existing metrics to determine budget against tools that could be implemented to improve estimates Project budgets and budgetary cycles using past data and new metrics Make results-driven decisions to produce more accurate estimates Translate lessons learned into scientific methodology Apply metrics for future planning

Establish More Effective Capital Projects Integration with Turnarounds

Delineate responsibilities for clear oversight Establish a line of communication between project coordinators and stakeholders for more efficient planning Communicate and comprehend project expectations Frontload collaborative effort s to avoid rewriting projects Weigh upfront integration vs. backend integration

Overcome Resource Challenges to Maintain Schedule and Cost

Detail persistent drivers of resource depletion to supplement planning scope; including personnel, equipment and budget Think outside the box to uncover creative solutions to obtain necessary budget Draw the connection between resource availability and planning schedule to overcome setbacks Set a precedent for a more targeted approach going forward

Bundle Work Packages as a Tool for Project Management

Bundle projects to encourage more strategic planning Specify when and where work bundling is most applicable Expand on bundling between clients and sites as necessary Consolidate turnarounds where possible for greater work efficiency Demonstrate the benefits of practical implementation of work bundling

POPULATING AND PROVING THE WORKFORCE

Enrich the Quality of the Turnaround Workforce to Maximize Operations

Identify gaps and weaknesses in the current workforce Detail a potent plan to acquire and effectively train new talent

Elaborate on the role of leadership in staffing and quality enhancement Promote accountability to drive up quality

Improve Worker Productivity to Avoid Turnaround Delays

Project and meet appropriate staffing needs Incorporate new technologies for cost-efficiency and ease of jobs Enhance maintenance strategy to prevent unanticipated work and avoid time delays Implement an environment of accountability to aid in production

TIGHTENING THE NUTS AND BOLTS FOR A STRENGTHENED MACHINE

Appraise the Latest Advances in Cleaning Technology

Review newer industrial cleaning technologies and practices Illustrate how the right technological tools advance projects Assess how frequently such practices should be implemented

Enrich Planning and Reporting By Using Management Software

Introduce the best project management software for plant maintenance Train staff appropriately to obtain the level of tech-savvy skills necessary for strong process Overcome technological hurdles for continued process improvement Grasp the benefits of using the right software tools for long-term improvement

Improve Inspections to Improve Routine Maintenance

Review inspection intervals to pinpoint the ideal frequency for which to conduct inspections

Pre-test process equipment to minimize scope Ensure solid maintenance standards are in place to avoid confusion and maintain project clarity Utilize valuable inspection tools to preserve maintenance integrity

Enhance Productivity of Confined Spaces Work

Exemplify the variety and types of recent problems encountered when working in confined spaces Discuss new legislation detailing industrial hygiene, exposure limits, ventilation Explore available technological solutions like ultrasonics and gas detection equipment Apply successful mechanisms to related problems to fulfill requirements

Evaluate Newest Safety Practices to Achieve Zero Reportables

Develop safety plans through detailed risk assessment Ensure strong safety standards and practices to avoid incidents Sift through instances of zero reportables to identify practices to adopt Incorporate safety as a culture to permeate every activity and promote plant health Employ robotics and acquiring technologies to improve worker safety

CONTRACTORS CORNER: A 360 VIEW OF BEFORE, DURING AND AFTER

Include Contractors in Front End Loading for Clarity of Role and Scope

Determine key areas of contractor involvement for clearly stated intentions and action points Outline main plant and contractor points of contact from the onset

Collaborate on a strategy to keep work on schedule Overcome obstacles and use them as a tool in future planning

Firm Bid Or Time and Material: Issuing Most Effective Contract Type

Decide which form of contract is most complimentary to project scope Understand the advantages and disadvantages of each route Identify potential issues once a contract type has been selected Use reporting variances to the advantage of the turnaround

Pros and Cons of Managing a Diversified Contractor Workforce

Weigh your contracting options and their value with your jobs in mind Anticipate the level of diversity that would best support plant objections Pare down oversight where applicable for more efficient use of time Experiment with options without losing productivity time

FINESSING OVERALL TURNAROUND STRATEGY FOR FUTURE SUCCESS Use Reporting History to Refine Planning and Establish Best Practices

Determine an ideal strategy and frequency to evaluate reports and data Transform lessons learned into usable corporate standards and

requirements Inspire corporate innovation through proven methods and takeaways Esteem integrity and progress to advance corporate goals Integrate best practices for the next turnaround

Address the Importance of Logistical Factors inOverall Project Scope

Nail down which aspects of logistical factors tend to be overlooked in planning Draw the connection between logistical importance to successful projects Track the flow of materials through the time of receiving to staging to issuing to returns, to determine what works well Account for specific cases of logistical falter to improve timeliness in turnarounds Communicate this message to planners and operators to ensure improved productivity

Summarized above are success factors proven over decades of industry experience.