www.glceurope.com
Eric Scott
Turnaround and Shutdown Management
MasterClass
Online MasterClass 17-19 May, 2021
Learn about the execution and commissioning of Chemical Plants turnaround
learning outcomes / KeY taKeaWaYs
• Enhancethecompany’sstrategicTurnaroundcapabilities• Improvethecompany’sapproachtoplanningandscheduling• Provideaframeworkforeffectiveturnaroundexecution• Highlighttheuniquesafetyrequirementsofturnarounds• Fostertheoneteamapproachtoturnarounds• ToensureasafeandorderlytransferfromTurnaround
phasetoStart-upphase• Provideacomprehensiveknowledgebaseforturnarounds• Demonstratethelatestplanningtechniquesforturnarounds• Toshareideasandissues
Turnaround and Shutdown Management
MasterClass
[email protected] +36 1 848 0515www.glceurope.com
17-19 May, 2021Online MasterClass
Who Should Attend?
eVent IntRoduCtIon
methodology
This workshop is designed to be beneficial to all individuals who interface with or are involved
in the planning, preparation, execution and commissioning of Chemical Plants during and fol-
lowing a turnaround. It is especially useful to managers, engineers, operations, planners, sched-
ulers, logistics coordinators, cost managers, and supervisors. It would also be of use to safety
officers, inspection and engineering personnel in order to increase their level of awareness of
the workings of turnaround management.
The planning, preparation and execution of a turnaround is a complex undertaking that
demands an effective strategy, a high degree of control and great attention to detail. It also
requires a profound understanding of the critical elements that go to make up a turnaround
and the drivers and constraints that shape the event. This requires involvement of every level
of the company from senior management who set the framework for the event through to the
craft personnel who perform the actual work.
The shutting down and start up phases of a turnaround are critical to the success or failure of
the event and as such must be planned and prepared in as much detail as the mechanical phase.
The Course is the product of over 30 years of practice by turnaround professionals working in
different industries in many countries around the globe and its principles are embodied in the
“Model of Excellence for Turnarounds” that forms the central pillar of the workshop.
The basic principles of the methodology are:
There are only two types of work on a turnaround, routine and unexpected. If the routine is
under control there is time to deal with the unexpected but if the routine becomes unexpected
the unexpected may become catastrophic.
Each module offers a practical approach with examples that draw out and develop participants
learning and experience in addition to that offered by the workshop.
Turnaround and Shutdown Management
MasterClass
[email protected] +36 1 848 0515www.glceurope.com
17-19 May, 2021Online MasterClass
Eric Scott is an acknowledge expert in the field of Turnaround Management who has worked
and consulted internationally. He is accomplished in many aspects of maintenance, projects,
construction and turnaround management. He has specialised in managing turnarounds and
similar projects from concept through to completion in a wide range of industries including
Nuclear, Offshore, Petrochemical, Refining and Manufacturing.
Spent 35 years with ICI most of which was in senior management roles. For 5 years as ICI’ s Senior
Inspection Engineer responsible for the registration and inspection of pressurised systems
throughout the company. Followed by 30 years in Turnaround Management, responsible for
setting up ICI’ s Turnaround Management Organisation, including three years as the Senior
Manager for the companies International Turnaround Management Group. In 1997 seconded
from ICI to Petronas Malaysia as Senior Turnaround Manager - Turnaround Group responsible
for setting up a turnaround management organisation responsible for the management of
turnarounds throughout the 40 operating units including the recruitment and training of all
personnel. This group undertook some 20 turnarounds per year.
Author of ICI’s “Model of Excellence in Turnaround Management
Author of Sellafield Nuclear Group - Turnaround Management Methodology
Author of Advanca (PTA) Turnaround Management Methodology
Author of OGP (Petronas) Turnaround Management Methodology
Meet the Trainer:
Eric ScottMaintenace and Turnaround Consultant
Turnaround and Shutdown Management
MasterClass
[email protected] +36 1 848 0515www.glceurope.com
17-19 May, 2021Online MasterClass
daY 1
Coffee Break10:30
Lunch Break12:30
09:00
08:30
10:45
Introduction to Outage Methodology
Initiating the Turnaround (Steering Group)
• Business contribution (dealing with boundaries)• The principles of work management• 4 phases of the Turnaround (exploring the 4 phases)• Overview of Turnaround Methodology• Need for the Turnaround• Understanding the customer• Benchmarking data (benchmarking against best practice)
• Introduction• Turnaround Policy (size, duration, frequency)• The steering group (setting policy, objectives and KPI’s)• Duration - what to consider before declaring a duration• The benefits of good Front End Loading (data gathering)• New Techniques (reduction in work scope)• The Turnaround Manager (translating policy into actions)• Preparation Team (creating a preparation program)
END End of Day 115:00
13:00 Worklisting
The Plan
• Introduction• Integration of functional support groups (to aid planning)• Maintenance Work scope• Operations work scope (management of plant surveys)• Shutdown and Start-up mechanical support• Work list Meeting (generating the ideal work list)• Meetings to aid the work listing process validation of work scope• Unnecessary Work
• Introduction• Planning Systems (What planning approach is required)• Database• Knowledge of Assets• Major Tasks• Small Tasks• Bulk Work• Fully integrated Shutdown and Start Up Logic• Scheduling the Work• The Turnaround Plan• Project Team approach to planning• Scheduling process (optimization)• Input to the Planning Process (what level of planning is required)• Scheduling Shutdown and Startup Plans• Monitoring Progress (updating the schedule)
Connecting to the online MasterClass
All dates and times are expressed in UTC/GMT+2 on the Agenda (CET Time Zone)
Turnaround and Shutdown Management
MasterClass
[email protected] +36 1 848 0515www.glceurope.com
17-19 May, 2021Online MasterClass
daY 2
Coffee Break10:30
09:00 13:00
08:30
Preparation Estimating and Cost Control
ResourcesSite Logistics
• Controlling Turnaround Materials• Long Delivery Items• Pre fabrication• Specialist technologies• Vendors representation• Preparation Framework• Meetings to aid preparation• The Team
• Introduction• Initial Estimate• Proposed Cost Estimate• Approved Turnaround Budget• Cost Centers• Controlling Costs during the Turnaround• Closing out Costs and reporting• What is the true cost of the turnaround
• Identification of work skills and numbers• Optimisation of job methods and resource
numbers• Optimisation of working patterns• Adequate management and supervision• Wrench Time• Skills tests• Resource problems
• Defining logistics (getting it right first time)• Critical relationship (aligning planning with logistics)• The elements of logistics (organizing what we need)• Early procurement (facilitates on-time delivery)• Organising Stores and Material delivery (bar-coding
for traceability)• Controlling by plot plan (what goes where and when)• Site clearance and hand back (leave the plant as you
find it or better)• Handover from turnaround back to operations
10:45 Turnaround Organisation/Training
Contractor Issues
• Basic Principles (factors that influence team design)• Single Point Responsibility• Constraints• The Hierarchy• Technical Support• Operational support (allocation of operational
personnel)• Single integrated team with Operations, Mechanical
and Contractors• Sample Organisation - preparation execution, start-up• Roles and Responsibilities• Other Organisational options
• Contract Styles (analysing different types of contracts)
• Contractor selection strategy (the upside and the downside)
• Contractor audit process (ensure competent contractors are engaged)
• Control of contractor performance (commercial awareness)
• Contractor development (benefits of partnering approach)
• Organisation Combination• Productivity Sampling (value for money)• Managing the Sub Contractors
Connecting to the online MasterClass
All dates and times are expressed in UTC/GMT+2 on the Agenda (CET Time Zone)
END End of Day 215:00
Lunch Break12:30
Turnaround and Shutdown Management
MasterClass
[email protected] +36 1 848 0515www.glceurope.com
17-19 May, 2021Online MasterClass
daY 3
Coffee Break10:30
09:00 13:00
08:30
10:45
14:50
Executing the Outage Quality management
Performance Monitoring / Closing the Turnaround
Start-up Planning
• Shutting Down the Plant• Role of Operations during execution• The Routine• The Unexpected• Control of work• Control of Emergent work• Event control• Trip and Alarm Management• Environmental control during execution activities• Permit to Work management• Starting Up the Plant
• Introduction • The Quality System in relation to
Turnaround• Controlling Quality through Preparation,
Execution and Post Turnaround Phases• Continual Improvement• Engineering Systems of Work• Quality investigations
• Introduction• Demobilization of the Site• Final Inspection and Handover• Post Shutdown Critique/debrief• Final Outage Report• Turnaround Data (Productivity, planning,
Benchmarking, KPI’s)• Auditing• How to audit• What to audit• Benchmarking• What is benchmarking• How to benchmark• Measurement• The importance of measurement• What to measure• Productivity The importance of
measurement
• Start-up Manager (what is his role and responsibility)• Start-up team (integrated team turnaround and
operations)• Training needs (historical start-up issues, Knowledge
of assets)• Hand back from Turnaround team to Start-up Team
(Managing the process)• Start-up safety and risk assessment (To ensure all
aspects are covered)• Developing a start-up strategy• Procedures and checklist development• Performance and acceptance testing• Managing reservation lists (mechanical problems
which arise during start-up)• Checking and commissioning projects/Mods
Lunch Break12:30
Safety Management
Feedback/Evaluation Session
• Introduction (defining magnitude and probability)• Management of, and responsibility for Safety• Safe Systems of Work (permit to work, rules,
regulations, safety audits)• Complying with safety• Planning for Safety (controlling safety inputs)• Environmental issues during Shutting Down and
Commissioning• Safety Team Training• Toolbox Talks• Walk the Talk sessions• Job Safety Analysis• Environmental Plan• Accident investigations• Safety Auditing• Job Freeze• Emergency Procedure• Safety Passport
Connecting to the online MasterClass
All dates and times are expressed in UTC/GMT+2 on the Agenda (CET Time Zone)
END End of Day 315:00
Turnaround and Shutdown Management
MasterClass
[email protected] +36 1 848 0515www.glceurope.com
17-19 May, 2021Online MasterClass
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