5 Stages of a Plant Turnaround Project

1. 5 Stages of a Plant Turnaround Project .

2. . AA plant turnaround or shutdown is referred to as the process of shutting down a plant or part of a plant for any repair, replacement or maintenance works. It is not easy as it sounds, because shutting down a part of a large plant for sometime can affect the industry in numerous ways slowing the whole process. Thus, everything has to be carefully planned before shutting down. Turnaround project manager must ensure that it is a smooth shutdown of the plant which will not cause overt delays and budget overruns.

3. . Here is the list of the 5 major stages of the shutdown process: • Scoping Stage Preferably known as the foundation stage of the shutdown process. It is the entire sketching period of the process, defining the objectives, business goals, forming a team, committee, setting milestones to be achieved on each phase of the project, etc. Complete safety of the workforce, cost reduction techniques and operational efficiency are among the top priorities in objectives. This stage decides the correct date of the shutdown and its duration.

4. Execution Stage Execution is the part where all the theories, outlines and plannings are getting into serious action. A shutdown execution stage is conducted by supervisors, who monitor the completion of each work and report back to the shutdown scheduler. Scheduler updates the worksheets and overlooks whether the work of repairing, replacing, maintenance etc. are done on time. Every equipment is double checked for better performance before the operations are resumed. • Evaluation Stage An analysis section has to be conducted soon after a plant shutdown for a detailed evaluation. It can be done in the form of a questionnaire distributed among the workers or supervisors involved in shutdown execution or in the form of a post-shutdown meeting, which is a great way of gathering feedback on the strategic turnaround process. .

5. Whichever is the method of evaluation, it must have the basic questions about the issues faced during the shutdown and different opportunities of improvement for future shutdown plans. • Planning Stage Planning stage focuses on the part of making an outline on how the work is going to be accomplished. Calculating and scheduling manual labor, setting the right equipment, materials, tools, estimating the overall cost etc. comes within the stage. By the end of this phase we have a complete list of job tasks assigned to workers, required set of machining equipment, heavy lifting equipment, hand tools, specialist tooling etc. arranged throughout the duration of the shutdown.

6. . • Scheduling Stage This stage completely runs around time restraints, ensuring the supply of needed equipment, materials, tools etc. according to the shutdown timetable. This stage is responsible for the completion of works in the allocated time, because now is the phase in which time is distributed among all parts of the maintenance activities.

7. . Looking at a plant turnaround or shutdown process as a whole, it is overwhelming and might seem flying overhead. But a careful breakdown of the entire processes into various stages or phases and allotting responsible members to each stage would make it a manageable thing to do. The best plant maintenance and turnaround companies in Saudi Arabia can ensure a strategic path through the different stages and an easy come out at the end, accomplishing the greatest and efficient shutdown of the era.

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