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Process Plants

In the process industry, shutdown and turnaround costs are responsible for an excessive amount of maintenance expenses. Process Plants: Shutdown and Turnaround Management explores various types of shutdowns, presents recommendations for better management, and offers feasible solutions to help reduce overheads. Because turnaround management is the largest maintenance activity, plant turnaround is the focal point of this text. The book details a plan to lengthen the interval between turnarounds, and curtail costs in process production management by at least 30 percent. This practical guidebook provides a thorough study of shutdown management, discusses different types of shutdown and managing events (emergency, unplanned, planned, and turnaround), and covers all aspects of plant turnaround management including startup, shutdown, and maintenance. It describes the five phases of shutdown management-initiating, planning, executing, controlling, and closing. It contains specific principles and precautions for successful shutdown planning, and highlights many aspects including turnaround philosophy, planning and scheduling, estimation, contractor management, execution, safety management, managing human resources, and post shut down review. Process Plants: Shutdown and Turnaround Management also includes topical information that readers can successfully apply to future shutdown projects. It is suitable for industry professionals and graduate students.
Product Details

Table of Contents

Introduction Process Plant Turnarounds Activities during a Turnaround Maintenance Philosophy Economics of Maintenance Management Types of Maintenance Activities Types of Shutdown Shutdown of Key Refinery Units Affecting Product Pattern Strategic Issues Turnaround Evaluation Initiating the Turnaround Initiation Developing a Shutdown Overview Strategic Plan Establish Shutdown Charter Initiating Scope Statement Appoint Shutdown Team Major Turnaround Milestones What Are the Shutdown/Turnaround Performance Criteria? Planning Kickoff Meetings Job of Planning Team Planning Step One: Developing the Shutdown Work List Planning Step Two: Identify Task Relationships Planning Step Three: Manpower Strategic Planning Planning Step Four: Estimate Work Packages Planning Step Five: Calculate an Initial Schedule Planning Step Six: Assign and Level Resources Planning Step Seven: Develop Procurement Plan Planning Step Eight: Develop Quality Plan Planning Step Nine: Develop Communications Plan Planning Step Ten: Develop Risk Plan Checklist Information Requirements for Planning Planning Is Not a One-Time Event! Estimating What Is an Estimate? Methods for Estimating Activity Duration What Is the Cost Baseline? Shutdown Contract Management What Is a Contract? Scope of a Contract Parties to a Contract Objectives Contractors Selection of Contractor Work Packages Contract Types Selection of Contractor Tender Evaluation Practices Management of Obviously Low Bids Subcontracts Terms of Payment Logistics Shutdown Organization What Is Involved in Effective Shutdown Organization? Turnaround Steering Committee Determination of the Skills Needed Shutdown Manager's Skill Requirement Leading Executing the Shutdown The Kickoff Meeting Safety Job Status Update Daily Schedule Reporting Status Tracking Shutdown Costs Preshutdown Job Long-Delivery Items Checklist Preshutdown Prefabricated Work Accommodation and Facilities Crowd Control Contractor's Insurance Certificates Safety Training Employing Barricades Emergency Showers and Eyebaths Special Machines Vendors Representatives Inspection of Equipment Traditional Inspection Practice: Background Inspection of Equipment Columns Vessels Heat Exchangers Demister Pad Refractory Pressure Safety Valves Inspection during Fabrication of New Piping External Corrosion Approaches for Other Equipment Types Shutdown Safety Hazardous Chemicals and Catalysts Common Hazards Safety Planning Safety Preplanning Evaluation and Selection of Contractors and Subcontractors Emergency Warning System and Procedures Communication Package Methods of Communicating Conducting Meetings Communication for Success Shutdown Control What Are You Actually Controlling? What Are the Baselines? Measuring Progress Quality Plan Shutdown Quality Deliverable Quality Planning Quality Risk in Shutdown Why Risk Analysis Is Necessary What Is Risk Management? What Are the Basic Steps in Risk Management? What Is Risk Identification? What Is Risk Quantification? What Are Risk Response Strategies? Why Do We Have Two Separate Reserves to Take Care of the Risks? Using a Risk Profile Historical Records Joint Integrity Managing Integrity Major Causes of Joint Leakage Corrective Action for Guideline and Responsibility Deficiencies Joint Assembly Procedure Conclusion Commissioning Systematic Commissioning Planning Mechanical Integrity What to Do in Checklisting Commissioning Process Commissioning Commissioning and Start-Up Period Minimum Facilities before Start-Up Pre-Start-Up Safety Review (PSSR) Customized Testing and Acceptance Methodologies Sequence of Commissioning Equipment Operating Procedures Postshutdown Review Contract Closure Administrative Closure Postevaluation Report Safety/Environmental Performance and Procedures Shutdown File Final Report Lesson Learned Session Celebrating Performance Performance Measure; Success Lean Shutdowns: Cut Waste Wisely from Your Outages Appendices Index

About the Author

Dr. Trinath Sahoo currently serves as senior manager at Indian Oil Corporation Limited (IOCL) and has 20 years of experience in the technical and management fields. His key areas of expertise include project engineering design and implementation, process plant maintenance, and troubleshooting and analysis of rotating equipment. Dr. Sahoo has a thorough knowledge of pump and compressor operation and maintenance; shutdown management, maintenance, and reliability; project and asset management; and advanced maintenance strategies. He has worked as a plant turnaround engineer for various projects and companies and has published papers in various international magazines and conferences.


"This book ought to be of value to the professional engineer new to the challenges of a plant turnaround. Scheduled and unscheduled maintenance are major issues for any chemical plant, refinery or installation. The loss of production and consequently loss of revenue needs to be managed as efficiently and as effectively as possible. Correct planning and execution of a turnaround requires considerable effort to ensure efficient return to full operating capacity. This book aims to highlight the main factors that must be taken into consideration from the planning stage through to execution and post shutdown reviews." --Professor Carl J Schaschke, University of Strathclyde, UK

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