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Turnaround Preparation, Planning, Execution and Review Process. Phase 1 Review Long Range Business Plan & Schedule. Phase 2 Prepare the Turnaround Criteria & Deliverables. Phase 3 Develop the Turnaround Work Scope. Phase 4 Complete All Turnaround Planning. Phase 5

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Prepare

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  1. Turnaround Preparation, Planning, Execution and Review Process Phase 1 Review Long Range Business Plan & Schedule Phase 2 Prepare the Turnaround Criteria & Deliverables Phase 3 Develop the Turnaround Work Scope Phase 4 Complete All Turnaround Planning Phase 5 Complete Pre-Turnaround Work Phase 6 Execute the Turnaround Phase 7 Complete Post Turnaround Documentation & Review No No No No No No No • Endorser: • President, Refining • Decision Executive: • Vice President, Refinery Manager • Decision Review Board: • Maintenance Manager, Operations Director, Planning & Economics Director • Endorser: • Refinery Manager • Decision Executive: • Operations Director • Decision Review Board: • Complex Manager, Turnaround Manager, Engineering • Director, Planning & Economics Director, • Reliability Manager, Project Engineering Manager • Endorser: • Operations Director • Decision Executive: • Operating Complex Manager • Decision Review Board: • Planning Engineer, Turnaround Manager, Project • Engineering Manager, Reliability Manager • Endorser: • Operations Director • Decision Executive: • Operating Complex Manager • Decision Review Board: • Planning Engineer, Turnaround Manager, Project • Engineering Manager, Reliability Manager • Endorser: • Operations Director • Decision Executive: • Turnaround Project Manager • Decision Review Board: • Turnaround Core Team • Endorser: • Operations Director • Decision Executive: • Turnaround Project Manager • Decision Review Board: • Turnaround Core Team • Endorser: • Operations Director • Decision Executive: • Operations Complex Manager • Decision Review Board: • Maintenance Director, Planning Engineer, Turnaround • Manager, Project Engineering Manager, • Reliability Manager Are the deliverables complete and adequate? Are resources adequate? Are the plans competitive? Is the execution plan complete? Will plan meet short range plan? Is plant and off-plot ready? Will scope meet long range plan? Turnaround CloseoutComplete? From Phase 7 Is plant on-test? Deliverables met? Yes Yes Yes Yes Yes Yes Yes Prepare Review Plan Execute • Frozen work list • Planning & labor forecast • Prelim. execution plan • Planning schedule • Procurement plan • Audit report • Core Team • Planning schedule • Opportunity & framing document • Planning and labor forecast • Stakeholder communication plan • Execute as planned • Schedule reports • Cost reports • Lessons learned • Pre Startup Safety Review • Final execution plan • WOs, Lists, procedures • Final AFE • Audit Report • Training plan • Schedule & cost reports • Field mobilization • Pre-work • Clean plant • Final reports • Plan for next Turnaround • Audit report • Long Range Turnaround Schedules • Budgets • Short range plan Return to Phase 1 Start Here • Team Leader: Planning & Economics Director • Team: • Turnaround Manager • Project Engineering Manager • Operations Director • Reliability Manager • Team Leader: Turnaround Project Manager • Team: • Operating Representative • Reliability Representative, Inspection • Design Engineer • Process Engineer • Capital Project Manager • Maintenance Representative • Team Leader: Turnaround Project Manager • Team: • Operating Representative • Reliability Representative, Inspection • Designs Engineer • Process Engineer • Capital Project Representative • Maintenance Representative • Contractor Representative • Team Leader: Turnaround Project Manager • Team: • Operating Representative • Reliability Representative , Inspection • Designs & Process Engineer (1 each) • Capital Project Representative • Maintenance Representative • Contractor Representative • Team Leaders: Turnaround Operations Coordinator & Maintenance Supervisor • Team: • Operators • Mechanics • Engineers • Inspectors • Contractors • Team Leaders: Maintenance Supervisor & Turnaround Operations Coordinator • Team: • Operators • Mechanics • Engineers • Inspectors • Contractors • Team Leader: Turnaround Project Manager • Team: • Operating Representative • Reliability Representative, Inspection • Designs Engineer • Process Engineer • Capital Project Representative • Maintenance Representative • DELIVERABLES & DOCUMENTS • Short Range Turnaround Schedule • Long Range Turnaround Schedule • Short and Long Range Budgets (Phase 1 Estimates) • FOCUS AREAS • Determine local and national mechanical labor force limits • Review policies and regulations impacting turnaround requirements • API/Boiler Codes/Laws & Regulations / RBI • Review Unit Performance vs. Benchmarks • Intensive Process Review • Yield / Energy / Reliability / OPEX • Turnaround interval / Cost /Duration • Interval Limits • Determine Capital Requirements • Environmental Compliance • Market Needs • Technology Gaps • Reliability Improvements • Plan to Minimize Lost Profit Opportunities • Value of Downtime • De – cluster the Turnarounds • Coordination with San Antonio • Market Conditions and Changes • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Solomon Study • Business Plan • API / Boiler Codes / Company Specs • Plant Inspection Plans • Intensive Process Review • Lessons learned / Final Report from Last Turnaround • Turnaround Process Checklist • Long Range Capital Plans • APN Tool Set • TIMING – PHASE 1 • On-going, part of annual planning cycle • DELIVERABLES & DOCUMENTS • Core Team • Turnaround Philosophy • List of Stakeholders • Stakeholder Communication Plan • Turnaround Planning Milestone Schedule • Preliminary Planning-Resource Forecast • Preliminary AFE • FOCUS AREAS • Dedicate resources • Define value of plant downtime • Determine Solomon targets • Define work list criteria • Review of Turnaround history & lessons learned • Define interval and limits • Complete On-Stream-Inspection • Perform RBI study • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Change management process • Turnaround Planning Process Overview • Define roles & responsibilities • Input checklist • Solomon RAM Tables • Inspection Records • Computerized Maintenance Management System • Long Range Turnaround & Capital Plans • Incidents & Worst Actor Equipment • RBI Process • Turnaround Process Checklist • Lessons learned / Final Report from Last Turnaround • APN Tool Set • TIMING, PHASE 2 COMPLETED • • 24 - 15 Months Prior to Turnaround • DELIVERABLES & DOCUMENTS • Frozen Work List • Planning-Resource Forecast • Preliminary Execution Plan • Contracting Strategy • Labor Loading Estimate • Safety Plan • Environmental Plan • Facilities Plan • Operating Procedures • Phase 3 Estimate and Schedule • Procurement Plan • Planning Schedule • Peer Review / Scope Review Report • FOCUS AREAS • Finalize all inputs • APN review data • On stream inspections • Incidents • Worst actors • Inspection History • Maintenance Backlog • RBI Study • Safety / Environmental • Capital Plan • Turnaround History • Eliminate all non-turnaround work • Evaluate key plant reliability concerns • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Turnaround philosophy document and criteria to Screen Potential Work Items • Peer Review / Scope Review • Self review or use APN Tools • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PHASE 3 COMPLETED • 12 Months Prior to Turnaround • DELIVERABLES& DOCUMENTS • Post Turnaround cleanup of unit and staging areas • Final Report / Metrics • Starting place for next Turnaround • Preliminary repair and replace work list • Action items and owners • Meeting schedule for next Turnaround • Audit Report • FOCUS AREAS • Demobilize contractors • Resolve excess materials • Communicate lessons learned • Publish recommendations for future Turnarounds • Update inspection & repair history • Update Turnaround history database • Complete post-Turnaround MOC requirements • Complete APN review • Stakeholder communications • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • RBI process • Peer Review / Results and Lessons Learned • APN Review • Scheduling & planning software P3 • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PERFORM PHASE 7 REVIEW • • 3 Month Post Turnaround • DELIVERABLES & DOCUMENTS • All Work Instructions, Lists and Procedures • Final Execution Plan • Organization Chart • Contracting Plan • Inspection Plan (1st Third) • Safety Plan • Environmental Plan • Facilities Plan • Operating Procedures • Tank and Line Plan • Critical-Path, Manpower-Loaded & Leveled Schedule with operations • Completed Phase 4 Estimate • Risk Assessment & Mitigation/Contingency plan • Communication Plan • Final Approved AFE • APN or Peer Review Report • FOCUS AREAS • Complete shutdown & cleanup plan • Complete commissioning and startup plan • Complete work orders, lists and procedures • Constructability reviews • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Schedule Software • Addition Work Control Process • Work Order, List and Procedure Completion Rate • Peer Review / Critical Path Challenge • Self- turnaround review or APN Tools • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PHASE 4 COMPLETED • 4 Months Prior to Turnaround • DELIVERABLES & DOCUMENTS • Training plan • Field mobilization and logistics plan • All pre-work complete • Schedule and cost reports ready • FOCUS AREAS • Train operators, mechanics, supervisors • Work scope • Procedures • Train for contractors • Safety • Maintenance specifications • Mobilize execution team • Set up safety, health, environmental requirements • Complete MOC requirements • Install temporary connections for cleanup • Hang all tags • Stage tools, blinds and materials • Begin cost tracking and reporting • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Turnaround execution plan • Scheduling & planning software - P3 • Additional Work Control Process • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PHASE 5 COMPLETED • • Feed pulled • DELIVERABLES & DOCUMENTS • Execute turnaround per plan and schedule • Pre start up safety review complete • Daily schedule and cost reports • Lessons learned captured • FOCUS AREAS • Conduct safety audits • Hold daily Turnaround meetings • Monitor schedule float and critical path • Prepare plan for next shift • Finish inspection in 1st third of turnaround • Monitor cost tracking and reporting • Review and document MOCs • Review and process additional work • Document all repairs • Manage QA / QC • Manage inter-plant coordination & communication • Stakeholder Communication • TOOLS & PROCESSES • Decision making process • Problem solving process • Meeting & communication process • Quick MOC process • Turnaround Execution Plan • Scheduling & planning software • Additional Work Control Process • Risk Mitigation/Contingency Plan • Turnaround Process Checklist • Stakeholder Communication Plan • TIMING, PHASE 6 COMPLETE • Feed in

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