PLANT TURNAROUND – #1 EXPERTS POINT OF VIEW FOR SUCCESSFUL EXECUTION
Nooter’s Plant Turnaround experience has been unmatched in the last 60 years, so we asked some of our expert Plant TAR leaders to share key advice. First, let’s define a plant turnaround (TAR). By definition, it’s a planned, periodic event where one or more processing/production units are temporarily removed from service. The purpose of the event is typically to perform maintenance such as the inspection and repair of equipment. It is also an opportunity to replace process materials and equipment that are worn out or broken and have reached their useful life. Both of these activities restore the life cycle of the asset base and ensure safe and efficient operations between TAR events. Often this work can only be performed when the processing/production units are not in service. TAR management is the greatest maintenance activity at a plant or refinery and is also a hefty investment of time, effort, and money.
Managing turnarounds requires expert preparation, communication, planning, scheduling, execution, as well as control to reach clients’ goals: quality, cost, schedule, and safety.
Our pros weighed in on these 7 Plant TAR focus areas:
Preparation: Equipment that requires maintenance, repair, and/or replacement should be known well in advance, as well as resources, equipment, and personnel needs. With that said, unplanned but necessary modifications and revisions may still happen during the turnaround, but strong and thorough preparation can allow these unplanned changes to be incorporated into the schedule and completed safely.
Communication: Before planning, scope definition, scheduling, or implementation, all TAR participants should be contacted and involved early on as open communication is key to the entire process. We provide numerous communication methods/channels for easy access to important turnaround information.
Planning and Scope: Once the scope is defined, supporting tasks should be prioritized and assigned. Then materials and skilled workers can be sourced and budgeted for, and the normal operations can be prepared for change. Risk assessments should be completed so potential issues can be resolved. The number of work items in the turnaround is a major consideration for safety, so we review the schedule closely to identify potential work items to reduce or perform
during normal operations.
Scheduling: Prepare a solid schedule. The schedule should ensure there will be no new potential danger added. Make the schedule as simple as possible and note any work that can be done during normal operations.
Pre-TAR Execution: We educate and re-educate all workers about safety. This is the time to inspect all safety equipment and PPE, as well as working tools. De-energize necessary equipment and perform Lock-Out Tag-Out to secure from an unintended operation.
Execution: This phase covers the implementation of the planned activities. Keeping schedules updated and maintaining standards is essential to efficient operation, and management teams should verify they have dependable monitoring means. This portion of the Plant Turnaround process includes the return to function and reporting on that restart. Note: New findings may be identified during the turnaround, or maintenance may propose additional repair or replacement items. The key is to ensure risk assessments are performed for any unplanned work.
Evaluation and Performance Measurement: This includes data/metrics collection and the ultimate goal of improving overall performance. Typical measurement goals include zero injuries, on budget, on schedule, amount of planned work versus unplanned, equipment commissioned to the procedure, speed of the plant returning to full production, and other applicable KPIs.
Nooter has the expertise to execute a wide range of Plant Turnaround services safely and successfully, from Routine Maintenance and Emergency Repairs to Major Shutdowns and new Capital Projects. Our project teams follow a methodical framework to plan, schedule, staff, and execute turnarounds of all sizes, anywhere they’re required.
If you need to “Talk TAR” with one of our experts, contact us today!