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Turnaround and Shutdown Operations in Refineries | 10th- 14th February 2025

This 5-day training program covers the intricacies of refinery shutdowns and turnarounds, providing participants with the tools and methodologies required ... Show more
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Course Overview

This 5-day training program covers the intricacies of refinery shutdowns and turnarounds, providing participants with the tools and methodologies required to effectively plan, execute, and evaluate these critical operations. The course covers essential topics, including asset failure analysis, work sequencing, cost control, and performance measurement, ensuring participants can optimise refinery life cycles and achieve turnaround efficiency.

Course Objectives

By the end of this course, participants will be able to:

  1. Distinguish between shutdowns and turnarounds and their implications for refinery operations.
  2. Conduct failure analysis and implement reliability-centred maintenance strategies.
  3. Develop detailed shutdown plans, including work breakdown structures, resource allocation, and scheduling.
  4. Apply project management techniques for time optimisation and cost control during shutdowns.
  5. Utilise performance indicators to assess turnaround effectiveness and implement improvements for future operations.

Target Audience

  • Maintenance and reliability engineers in refinery operations.
  • Shutdown and turnaround coordinators and planners.
  • Operations managers and supervisors overseeing refinery lifecycle optimisation.
  • Procurement and inventory specialists involved in shutdown planning.
  • Technical professionals aiming to enhance expertise in refinery maintenance strategies.

 

Daily Agenda

Day One: Refinery Shutdown Types & Asset Pairing

  • Definitions of shutdown and turnaround.
  • Material failure and degradation in refineries (API 579 application).
  • Sensitivity of refinery structures and units to failure.
  • Failure rate mathematics: foundations of reliability-centred maintenance.
  • The role of shutdowns in the refinery lifecycle.

Day Two: Shutdown & Turnaround Planning

  • Refinery work order (WO) system input for planning.
  • Estimating work size using API 579 and creating a work breakdown structure (WBS).
  • Developing an organisational structure to manage the shutdown.
  • Identifying and sourcing spare parts and materials for shutdown operations.
  • Determining personnel requirements: internal staff versus subcontractors.

Day Three: Organising the Shutdown Time Sequencing

  • Optimising work sequencing for efficient execution.
  • Managing constraints: materials, personnel, and contractors.
  • Aligning shutdown schedules with the refinery’s lifecycle.
  • Application of timing techniques, including CPM (Critical Path Method) and PERT (Program Evaluation and Review Technique).

Day Four: Control of Shutdown Time, Costs & Work Quality

  • Monitoring progress with Gantt charts.
  • Budget tracking using S-curves.
  • Allocating financial reserves to address uncertainties.
  • Adhering to ISO/API standards for work handover processes.

Day Five: Shutdown Performance Analysis & Turnaround Efficiency Measurement

  • Evaluating asset turnaround performance indicators.
  • Assessing workload and planning performance metrics.
  • Analysing turnaround cost-effectiveness and operational efficiency.
  • Archiving shutdown and turnaround data for future planning.
  • Formulating recommendations to improve subsequent operations.

Why Choose this Course?

This course offers a comprehensive approach to refinery shutdowns and turnarounds, integrating technical insights with practical methodologies. Through case studies, hands-on exercises, and industry best practices, participants will be equipped to minimise downtime, optimise costs, and extend refinery asset lifecycles effectively.

Learning Outcome

Upon completing this course, participants will:

  1. Gain expertise in planning and managing refinery shutdowns and turnarounds.
  2. Apply advanced scheduling and sequencing techniques to enhance efficiency.
  3. Monitor and control costs using tools like Gantt charts and S-curves.
  4. Evaluate shutdown performance using quantitative metrics.
  5. Develop actionable strategies for continuous improvement in turnaround operations.
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