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Managing Maintenance Shutdowns and Outages Agenda for 3-day course

Day 1 Planning the Shutdown

Mastering the Basics of Shutdowns, Turnarounds and Outages

  • Language definitions
  • Size of events matter
  • Basic Skill -Meetings Exercise and discussion
  • KPIs for a shutdown
  • Comparing and contrasting project management verses typical shutdown
  • Defining Constraints
  • Cover-up
  • Communications and presentations

Group activity: Quick report card Exercise

Putting the Shutdown into time -Phases of a shutdown

  • Scheduled Audits
  • Preparing a Typical Time line -exercise
  • Instituting a long term shutdown policy

Shutdown Organization

  • Insuring great communications
  • Shutdown team titles
  • Roles and responsibilities
  • Accountability tip

Master Checklist for Phase 1 Initiation Exercise

Scope of work -Inputs into the Shutdown

  • Examining the Sources of work
  • List of sources to check before closing the work list
  • Checklists for Infrared and Vibration inspection before shutdown
  • Work Validation ( get rid of duplication, subsets, and other non-essential work)
  • Packaging of work for bidding
  • Prioritization of work

Shutdown Planning- Individual job planning

  • Planning Thought Process
  • Special requirements of Large jobs
  • Planned Job package

Planning lead times Exercise

Estimating Exercise

Risk, safety and health

  • Threat matrix
  • How to run a Safer shutdown
  • Safe work process
  • Safety risk list
  • Accident reporting process
  • Managing other risks

Day 2 Scheduling the Shutdown

Scheduling (Project Management Techniques)

  • History of Project Management

Critical Path Method (CPM) Exercise

  • Key concepts for all PM techniques
  • Project management techniques
  • Gannt Charts, CPM charts
    • Display and Milestones
    • Dependencies
    • Float
    • Crashing
    • Resources
    • Logistics
    • Site plan

Managing the logistics' challenges in a shutdown

  • Effectively managing your personnel and material resources
  • Site set down plans
  • Questions to be able to answer
  • Strategic sourcing for parts, materials and supplies

Master Checklist for Phase 2 Planning, Scheduling Exercise

Contracting and Contract management

  • Legal framework
  • Tools of contracting: types, uses, important concepts
  • Legal Relationships
  • Avoiding problems
  • Example of a legal case study in shutdowns

Day 3 Executing, reporting on and Accounting for the Shutdown


  • Insure quality
  • Hold points
  • Shift schedules

Managing Execution

  • Shutdown the plant and Start-up the plant
  • Daily schedule and feedback
  • Shutdown review meeting agenda
  • Project leader failure techniques Exercise
  • Daily routine

Phase 3 Execution Master Checklist Exercise

Shutdown essentials
  • Accounting, costs and budgets
  • Completion
  • Reporting
  • Lessons learned
  • Files to keep and review

Phase 4 Completion of work Master Check list Exercise

Phase 5 Completion of project Master Check list Exercise

Wrap-Up Session

  • The final session reviews the topics that have been covered over the last two days,
  • Questions and discussion

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