Annual Shutdown: Share Your Feedback and Insights

I am uncertain about removing Operations, HSE, Admin, and Finance staff from the plant during a shutdown. I believe their presence is vital for work permits, HSE compliance, managing entry/exit of personnel and goods, and handling tendering processes. Will the Maintenance team be ready to restart operations when these staff members return from their holidays? I am unsure about pharmaceutical plants, perhaps they operate differently?

• 05-09-2024
• Simon Ward

As an automotive supplier, we carefully plan our shutdowns to coincide with the automotive industry's downtime. Our process typically begins in April for the July shutdown, ensuring that all necessary maintenance is completed without any interruptions for holidays. For example, infra red scanning is typically conducted in May, with the report usually available by the first week of June. Repairs are then scheduled to take place over a two-week period in July. It is also essential to ensure that there is adequate support staff for maintenance and that the stores are adequately stocked. This proactive approach helps us maintain operational efficiency and minimize disruptions in our services.

• 06-09-2024
• Chad Cook

In the permits processing at the plant, HSE (SHE in my case) is essential for safety compliance. Procurement and Finance are not involved as purchase orders are planned in advance. The Maintenance Stockroom, under the Maintenance Department, handles required goods and assists with tasks using forklifts. If needed, the Maintenance Supervisor or Manager will involve other department Managers. A distinction is made between plant shutdowns and manufacturing vacations, where operational tasks can be completed without interruptions from office personnel.

• 06-09-2024
• Mia Bailey

I selected "other" option. I have been involved in two turnaround projects, leading the most recent one. There are several key factors to consider when planning for a successful turnaround: 1) Marketing - oil prices are subject to various external influences such as political events (e.g. Chaves in Venezuela, War in Iraq), and internal demands for resources like asphalt. 2) School vacations - many employees are also parents, so scheduling around school breaks is essential. 3) Weather - working in outdoor environments during rainy seasons, snow, or ice can present challenges. 4) Manpower - hiring temporary workers when needed and monitoring the actions of competitors in the industry is crucial. 5) Security - preventing theft of tools and equipment is a priority. 6) Equipment rental should be considered in conjunction with manpower needs. 7) Special services like expatriate support, accommodations, and holidays must be planned for. 8) Safety is paramount, as a partially operational plant can pose greater risks than a completely shutdown one. 9) Supervision and 10) Having a sizable contingency fund in place for unexpected scenarios is essential for successful turnaround management. While some of these considerations may not be applicable to every shutdown, they serve as a helpful guideline.

• 06-09-2024
• Cameron Price

During turnarounds, Operations personnel are not able to take vacation as they are dedicated to the turnaround workforce.

• 07-09-2024
• Jasmine Howard

When planning for shutdowns, various technical and business considerations need to be taken into account, such as equipment maintenance requirements and scheduling conflicts with other departments. Cultural and local factors also play a role in this process, including popular vacation times, holidays, and the availability of childcare for employees with working spouses. Political issues, such as warfare or changes in leadership, may also impact shutdown planning.

• 07-09-2024
• Tina Murray

Have you ever experienced working outdoors in the rainy season or dealing with snow and ice in December? Living and working on a Caribbean island offers the advantage of enjoying sunny weather all year round, unless there is a particularly active hurricane season. Experience the benefits of a constant tropical climate in the Caribbean.

• 07-09-2024
• Olivia Brown

When determining the optimal timing for an annual shutdown, consider factors such as best practices, regulations, and the significance of this routine maintenance task. Is an annual shutdown simply a tradition or is it required by regulations? Why is there a push for an annual shutdown instead of less frequent maintenance checks? Before halting operations for this planned maintenance, ensure that there are valid technical and commercial justifications for doing so.

• 07-09-2024
• Isaac Lewis

Determining criteria for shutdown in industrial plants typically includes evaluating the rates of degradation in catalyst, static equipment, rotating equipment, and instrument trip/control loops. The decision on when to shut down is often influenced by regulatory inspections, especially in onshore facilities. While regulatory inspections are mandatory in deregulated industries, shutdown intervals are usually based on a plant's catalyst design life, falling between 2 and 3 years. Customary practices also play a role in determining shutdown schedules.

• 07-09-2024
• Jessica Freeman

Determining the optimal time for peak demand can vary based on various factors such as location, weather conditions, industry type, and competition for resources. For example, while some products like cars can be stocked, others like electricity cannot be stored. In regions like southern Australia, peak demand used to occur during winter months (June-August), but the rise in air conditioner usage has shifted the peak to summer. As global warming continues to be a factor, the timing of peak demand may evolve. Wishing everyone a Happy New Year with a smile from Ray.

• 07-09-2024
• Jack Parker

In the realm of scheduling maintenance tasks, Darth, Josh, and Ray, you have hit the nail on the head. There are guiding principles to follow rather than set recipes for success. Darth, effective scheduling hinges on pinpointing the best timing to minimize financial losses. It's crucial to time shutdowns when demand is low, skilled workers and spare parts are readily available, and weather conditions won't disrupt productivity. Planning, on the other hand, entails determining the scope of work, its frequency, necessary steps, technology utilization, risk assessment, and mitigation strategies. Remember, planning precedes scheduling, hence my query about the annual schedule. Josh, your insights are commendable, and it's worth noting that there are additional factors at play in scheduling maintenance tasks.

• 07-09-2024
• Bob Smith