Delivering industry Best Practices for managing the most Safe & Cost-Effective Shutdowns!

Course Overview

Planned Outages are required for plants or distribution facilities to carry out their scheduled preventative, regulatory or engineering work. The purpose of an outage is to maintain the equipment reliability, improve safety and ensure efficient operation while also achieving critical regulatory requirements. An outage is a very important function that has a direct impact on the profitability of a plant’s production and maintenance costs resulting from the expenditure of manpower, equipment and materials. Proper work preparation and scheduling can result in a significant “ROI.”

Shutdown / Turnaround / Outage (STO) Management is a 3 day training course designed to expose the detailed steps and strategic techniques necessary for STO improvement and effective completion. Attendees will learn industry best practices for minimizing the possibility of accidents, rework, and equipment failure and reduce the impact on manpower safety, equipment and operation safety.

Through our interactive and adult learning techniques, attendees will participate in table top exercises, scenario discussions and networking opportunities. Regardless of your level of expertise, you will gain the understanding of how industry “Best in Class” are utilizing Shutdown Specialists and how this knowledge can be used as leverage in your organization.

Learning Objectives

  • Define work scope and responsibilities for all personnel involved in each stage of the STO
  • Improve your plant reliability and equipment availability with an effective STO strategy
  • Learn how selecting work through a prioritization system can better control future maintenance costs
  • Minimize the possibility of liability by improving plant safety
  • Evaluate the management of equipment lifecycle through effective STOs

Who Should Attend?

Shutdown / Turnaround / Outage (STO) Management was designed specifically for individuals participating in or aspiring to the following:

  • Mechanical, Electrical, Production or Project Engineers
  • Procurement
  • HSE Advisors
  • Construction/Contractor Managers and Supervisors
  • Testing and Commission Engineers
  • Maintenance Managers, Supervisors, Planners & Schedulers
  • Key Operations Supervisors • Materials Management Managers/Supervisors
  • CMMS Administrator or Key Users
  • Key Maintenance Support Assistants
  • Maintenance Engineers (Functional and Reliability)
  • Other Stakeholders in the Work Planning Function

Course Outline (Day 1 – Day 3)

Day 1 Welcome & Introduction

  • Meet & Greet
  • Pre-Assessment

Module 1: Turnaround Management Introduction

  • Overview
  • Turnaround Philosophy
  • STO Phases
  • STO Management Systems
  • Exercise

Module 2: Plant Turnaround Process

  • STO Business Plan & Strategy
  • Organization
  • Planning & Scheduling
  • Execution
  • Controlling
  • Close-out & Analysis
  • Exercise

Module 3: Turnaround Organization

  • STOs Resource Evaluation Process
  • Roles & Responsibilities (RACI)
  • Common Responsibilities
  • Operations Responsibilities
  • Responsibility Details
  • Exercise

Module 4: Planning & Scheduling

  • Master Work Scope & Equipment Criticality
  • Comprehensive Work Packages
  • Estimating
  • Scheduling
  • Exercise

DAY 2 Module 5: Work Execution

  • Risk, Prioritization, & Contingency Planning
  • Work Execution Plan
  • Permitting
  • Daily Schedules
  • Exercise

Module 6: Logistics Plan

  • Overview
  • Lubrication basics – the anatomy of a lubricant – it’s a bundle of performance properties
  • Materials & Equipment
  • Exercise

Module 7: Contractor Management Plan

  • Use of Contractors
  • Manage the Bid Stage & Award
  • Effective Mobilization
  • Exercise
  • Managing STOs Safely
  • Pre-Start-up Safety Checklist & Sign-off
  • Exercise

DAY 3 Module 9: Critical Path Management

  • Critical Path Analysis
  • PERT & Gantt Charts
  • Understanding Networks
  • CPM Planning Steps
  • Float
  • Exercise

Module 10: Close-Out & Review

  • Overview
  • Records & Files
  • After Action Review (AAR) / Audit
  • Exercise

Module 11: KPIs & TASC

  • STO Key Performance Indicators (KPIs)
  • Turnaround Management System Checklist (TASC)
  • Exercise

Wrap Up

  • Course Review
  • Post Assessment
  • Certificates & Evaluations

Course Agenda (Day 1- Day 3)

7:30 Registration & Breakfast
8:00 Morning Session Begins
10:00 - 10:30 Refreshments & Networking 12:00 Lunch
1:00 Afternoon Session Begins
3:00 - 3:30 Refreshments & Networking 5:00 Finish of Day / Course

Course Format

This course will be held in a highly interactive workshop format with case studies and real-world examples. The material has been designed using Adult Learning Methodology that believes the ideal ratio for optimum learning and retention is 60%/40%:

60% - blended combination of discussion, practical exercises, simulations, & case studies 40% - material/slides

Participants will engage in interactive exercises and discussions throughout the course to ensure the material is not only taught, but can also be applied. Limited class size (15-20 participants) is strictly enforced to enhance individual learning experiences and interaction with the instructor and other participants.

Certificate of Attendance

Upon the successful completion of this course, participants will receive a Certificate of Attendance bearing the signatures of both the Instructor and Course Organizer.

Course Material

All participants will receive a hard copy of the course material.

Pre & Post Course Assessments

Each participant will complete a pre-course assessment to gauge their current levels of knowledge and experience. At the conclusion of the course, participants will then complete a post-course assessment to ensure the material was presented effectively.