Turnaround Maintenance
Definition :
In petroleum refining , turnaround
means
a
scheduled large-scale maintenance activity wherein
an entire process unit is taken off stream for an
extended period for comprehensive revamp and
renewal. This operation involves a lot of preparations
and requires many precautions, especially at during
startup.
Contents
Turnaround Maintenance
+ Objective / Purpose
+ Process / Procedure
+ Strategy Followed
+ Organogram
+ Key Achievement/Highlights
+ Key Learning
+ What made it happen & final success
+ Major Counts at a glance
+ Sep11 Cost : Budget Vs Actual
+ Duration Schedule Vs Actual
safety record.
To achieve the best quality of workman ship.
To complete the turnaround in the shortest possible time.
To complete the turnaround at the lowest possible cost.
Revamp Jobs for Refinery capacity augmentation from 14
MMTPA to 18 MMTPA.
CDU/VDU/SGU Revamp
FCCU Revamp
VBU to CDU Conversion Tie-ins.
SRU Revamp
Train: I integration Tie-ins.
Name
1
2
3
4
5
6
7
8
9
Head-Refinery
Chief Turnaround Manager
Overall Operation Co-Ordinator
Tech.Services Co-Ordinator
Construction Co-Ordinator
HSEF
Turnaround manager
Turnaround planning Co-Ordinator
Turnaround-MIS-Co-Ordinator
C Manoharan
Narada Singh
KC Swain
Satheesan V N
G G Mehta (EPIL)
Dr Gopal Jayaraman
P Rambabu
D D Chaudhari / Jayanti Vagdoda
Hembala Dixit
10
Operation Co-Ordinator
11
Ramesh Kumar
12
13
14
15
16
17
18
19
20
21
22
23
Revamp/Expansion Execution
Manager
Overall Tie-ins Co-Ordinator
Instrumentation
Electrical
Civil
EPS
Security
Admin
Reliability/Rotary/ Workshop
Commercial
RSM
J K Jani
RSM
TR - 0
TR - 1
TR - 2
TR - 3
TR - 4
TOPTM
Overview
Strategic Review
Scope
Cost
Schedule Preparedness
Ideal
Timing
Run Cycle (2)
Workscope Review
- 9 months
Execution Review
- 6 months
Preparedness Rev.
- 3 months
+1 months
{S R T C}
SAFETY
RELIABILITY
TIME-BOUND
COST-EFFECTIVE
+Preparation of TBRA for all Critical S/D activities e.g. Hot jobs,
Modification job, work at height or any other confined space jobs
Space for contractors offices have been provided in the S/D yard. Some of the
contractors will have to be located inside the units (from logistic point of view).
7) Resting Place :
Separate tents arranged for Dining and Rest room for different contract manpower as well
as for engineer. Near Shutdown yard to avoid manpower movement.
8) First Aid office:
Central first aid tent will be located in front of Lab near E-W road. It will be supplemented by
paramedic officer / doctor on round the clock basis and one ambulance.
9) Accommodation for Labour / Transport.
Accommodation for 10000 Labours have been booked in Labour colony.
For transporting Labours from labour colony to refinery, our trailers will be used and
necessary railing arrangement is being done in our workshop for safety. In addition to this
permission will be given for walking from labour gate to workplace on the fixed route.
10) Office space for foreign expatriates:
11 Timing:
and
standard
1
2
3
4
5
6
7
8
9
Head-Refinery
Chief Turnaround Manager
Overall Operation Co-Ordinator
Tech.Services Co-Ordinator
Construction Co-Ordinator
HSEF
Turnaround manager
Turnaround planning Co-Ordinator
Turnaround-MIS-Co-Ordinator
Name
C Manoharan
Narada Singh
KC Swain
Satheesan V N
G G Mehta (EPIL)
Dr Gopal Jayaraman
P Rambabu
D D Chaudhari / Jayanti Vagdoda
Hembala Dixit
ISBL: SKM Rahman
Utility: Chitti Babu
PIT/COT: Ajay Veer
Ramesh Kumar
10 Operation Co-Ordinator
13
14
15
16
17
18
19
20
21
22
Revamp/Expansion Execution
Manager
Overall Tie-ins Co-Ordinator
Instrumentation
Electrical
Civil
EPS
Security
Admin
Commercial
RSM
b.
c.
d.
e.
We treat contract manpower as our employee and provide all the facilities
like Accommodations/Food/Transport/Medical/Water/Tea-Snacks at site
only.
Use of new concepts and modernized gadgets e.g. providing lifts as high
as 90 Meters, Dehumidification /AC, Chemical decontamination etc.
Maximizing the pre turnaround activities e.g. 90% scaffolding, issuing of
100% bulk material/ spares and its prefabrication/ machining and placing
in position.
Daily Review and making rolling plan for speedy execution.
Timely supply of equipment and logistics arrangements
2.
a.
Optimise the use of Pigging machines in such a way that critical Heater
handed over with in minimum possible durations.
Use of new concepts and modernized gadgets e.g.SAF RAD
Radiographic machines so that other jobs can be continued.
Heater jobs divided in multiple zones so that welding jobs can be
performed at maximum locations at a time and saved lot of time.
Keep standby manpower for critical activities so that job shuld not suffer
at any cost.
b.
c.
d.
35 days
26 days
3924 Nos
74.66 Cr
74.69 Cr
70 Nos
15000 Nos
846 Nos
20 & 5 Nos
57 Nos
39 Nos
10 Nos
33 Nos
05 nos
26 Nos
50
12
2
20
09 Nos
06 Nos
12
3
2 nos
3
2 nos
3500 Nos
1618 Nos
2492 Nos
Sr.
Description
No.
Mechanical/Operations
total)
(Sub
Total
Budget- Budget ( Actual Actual
Total (
Service Material+ Material Service
Actual)
cost
Service)
s Cost
Cost
cost
15.86
40.10
55.96
18.49
35.79
54.63
B Electrical
2.52
2.22
4.74
C Instrument
2.99
0.99
3.98
2.01
1.64
1.90
1.26
3.91
2.90
D Civil
2.99
3.49
1.70
5.58
7.27
1.80
1.80
0.30
0.35
0.65
0.00
0.37
1.53
0.18
1.53
0.55
0.50
E Inspection
F Fire & Safety
G
0.00
1.51
1.51
0.09
2.34
2.43
Maintenance
supervisor/Engineers hiring
0.00
2.53
2.53
0.00
1.47
1.47
22.17
52.48
74.66
73.96
Justification
PLANNED
STOPPAGE DATE
& TIME
ACTUAL FEED
CUT OFF
STOPPAGE DATE
& TIME
ACTUAL FEED
CUT IN START UP
DATE & TIME
THANK YOU