You Can Get Ahead of Plant Maintenance
A plant shutdown, or turnaround, is a temporary closure of a building to perform maintenance. The main activities should be preventative in nature with the focus on equipment inspections. This is the best time to replace worn-out or broken process materials and equipment at their useful end-of-life. An effective plant shutdown should result in reduced unplanned downtime, reduced overtime, and greater operational efficiencies.
5 effective phases of a plant shutdown
Phase 1: Scoping (What to do)
The scoping phase is the foundation for a plant shutdown. Initial planning, scoping, and organization occurs during this phase. It’s important to build a strategy to address what you are going to do for each area of your operation: test, replace, repair, defer the work, or do nothing.
Phase 2: Planning (How to do it)
The planning phase represents the nuts and bolts of your strategy and how to accomplish the work. Basic requirements include a development of job tasks, and the steps, duration, and sequence. Resource planning is another decision you should make around people, material, tools, and equipment.
Phase 3: Scheduling (When to do it)
The outcome of your planning phase should drive your scheduling phase. It is also important to keep the shutdown as short as possible. Keeping the list short is a way to reduce cost and ensure the focus is on the work you can only perform during a shutdown.
Phase 4: Execution (Doing it)
After an extended planning period, the execution phase is where the rubber meets the road. Now is the time to inspect your equipment and put in place any corrective actions needed.
Phase 5: Wrap up (Evaluating it)
Phase 5 begins once you complete all the tasks associated with the shutdown. Conduct a post-mortem meeting to review the shutdown in its entirety.
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