The planning and management of start-ups and shut-downs in a process plant environment are becoming more complex and demanding; this course will explain and illustrate all these essential stages. To avoid unanticipated risks and costly delays, plant shutdowns and resume operations must be meticulously planned, managed, and controlled.

In contrast, well-planned and executed shutdowns result in improved preventive or emergency maintenance. This course has been designed to aid owners and contractors in achieving their turnaround goals by providing a comprehensive, in-depth examination of the subject matter.

AIBM has a “learn to ace” philosophy; our team consists of professional and expert educators who ensure that your abilities and skills are enhanced by effectively acquiring course-specific knowledge. This training session will teach participants the most recent techniques for organizing, supervising, and administering maintenance activities. In addition to scientific techniques and program materials, this course will provide numerous real-world case studies and implementations in an open discussion forum with the participants. Various instructional strategies are employed throughout the course to facilitate interactive (active) learning.

Certification Program Objectives: 

• Gain knowledge of effective personnel and logistical management for situations involving shutdowns and restarts.
• Understand how to precisely define, develop, and regulate the scope of closure and startup.
• Learn to execute proper closure and startup planning.
• Select performance metrics efficiently to ensure a smooth termination and restart.
• Learn how to engage contractors to ensure their dedication during shutdowns and relaunch.
• Demonstrate the use of rational and efficient planning strategies for closure and startup.
• Utilize industrial case studies to execute shutdowns and restarts methodically.

Certifying Examination:

• To be certified as CPPSTP, student should take up a 1.5 hours exam at the designated examination centers.
• The qualifying exam would consist of 50 multiple choice questions, testing core certification modules.
• Professionals with relevant experience and other qualifying criteria may be exempted from the examination.

Materials Provided:

• Presentation slides
• Study references

Certification:

Upon successful completion of the CPPSTP training, participants will receive a “Certified Process Plant Shutdown and Turnaround Professional” certificate.

Who Should Attend:

• Planning / Scheduling and cost control personnel Professionals and coordinators in charge of shutdown or turnaround.
• Technicians in Plant Engineering, Engineers in Maintenance, and System Engineers.
• Operators in the energy, hydrocarbon, chemical, and paper processing industries.
• Individuals/experts responsible for operation, maintenance, and troubleshooting

Course Outline:

Module 1: The Importance of Maintenance Shutdowns and Turnarounds in Leading Organisations 

• How shutdowns and turnarounds contribute to a leading  business
• Key success factors
• The three vital paths of shutdowns and turnarounds
• The difference between shutdowns and projects
• Shutdown and turnaround return on investment
• Shutdown and turnaround management self-assessment
• The shutdown and turnaround phases
• Reasons for shutdowns and turnarounds
• Critical Success Factors
• Shutdown functional areas and their practical contribution

Module 2: Shutdown/Turnaround Preparation

• Risk management
• Justification requirements
• Communications to stakeholders
• Shutdown roles and organization
• RASCI/RACI matrix for shutdown
• Preparation critical success factors
• Identify routine preventive maintenance (PM) to be included in the scope
• Identify routine condition-based tasks to be performed prior to shutdown and turnaround

Module 3: Shutdown/Turnaround Preparation Continued 

• Make use of CBM and degradation analysis to improve scope visibility.
• Use the notification process to manage the visibility of created scopes.
• Apply risk-based task selection methods to prioritize and challenge the scope
• Review, approve, communicate and freeze the scope
• The critical outcomes of planning
• The 5 Ms of maintenance work quality
• Job analysis and scoping
• Estimations
• Risk and contingency planning
• The use of planning templates
• Work breakdown structure

Module 4: Shutdown and Turnaround Schedule 

• Terms and concepts of scheduling
• Network display methods
• Apply the critical path method (CPM)
• Identify resource constraints
• Resource requirements based on CPM
• Resource smoothing
• Resource balancing
• Optimised resource profile
• Shutdown and turnaround budgets
• Allocate Shutdown Work – In-house and Contractors
• Types of contractors
• Types of contracts and criteria for selection
• The risks associated with employing contractors
• Benefits of using contractors on shutdowns
• Staying in control of the contractor

Module 5: Shutdown and Turnaround, Execution Control and Review 

• Shutdown work packaging
• Shutdown quality control
• Shift schedules
• Preparing equipment for the shutdown
• Daily schedules
• Dealing with emergent and additional work
• Control data
• Status accounting
• Controlling the shutdown
• S-curves
• Earned-value
• Shutdown performance indicators
• Shutdown and turnaround review meeting agenda
• Causes of shutdown failures
• Problems in shutdowns and their origins
• Start-up and commissioning
• Shutdown close-out reporting and review
• Shutdown closing out the review
• Overview of computerized tools
• Conclusion