Audel Managing Shutdowns, Turnarounds, and Outages

by Brown, Michael V.

• ISBN13: 9780764557668
• ISBN10: 0764557661
• Edition: 1st
• Format: Paperback
• Copyright: 2004-09-24
• Publisher: Audel

Summary

Don't shut down by accident A carefully planned shutdown will improve your plant's safety and efficiency, while one that "just happens" can be disastrous. Developed from the author's highly successful seminars, this book takes you step by step through successfully managing production shutdowns. Identify what must be done, schedule equipment and staff, use project-management software, and save both dollars and downtime. * Prioritize needs and identify what can be accomplished within time and budget constraints * Determine whether outside help is required * Schedule the order and priority of projects * Learn to use CPM (Critical Path Methods) or PERT (Program Evaluation Review Technique) * Plan for new or additional work that may arise during a shutdown * Report and document preparation and execution * Identify and record future needs the shutdown reveals

Author Biography

Michael V. Brown has held maintenance management positions and advised Fortune 500 companies. As a founder and President of New Standard Institute, he has designed and implemented maintenance management programs for a diverse group of clients.

Table of Contents

About the Author	xi
Introduction	xiii
Identifying the Work	1	(28)
Identifying the Work	2	(14)
Reviewing the Maintenance Backlog	3	(3)
Identifying Preliminary Work	6	(10)
Risk Management	16	(3)
Risk Identification	16	(1)
Risk Quantification	17	(1)
Risk Response Development	18	(1)
Risk Response Control	19	(1)
Defining and Limiting the Scope	19	(7)
Defining the Constraints of the Shutdown	19	(1)
Prioritizing the Proposed Work	20	(1)
Preliminary Estimates of Proposed Work	21	(3)
Determining Contract Work	24	(1)
Determining Internal Labor Demands	25	(1)
Job Input Cut-Off Date	25	(1)
Prioritizing Last Minute Requests	25	(1)
Summary	26	(3)
Planning the Work	29	(44)
Planning the Shutdown	29	(10)
The Shutdown Organization	30	(2)
Assigning Responsibility	32	(1)
Parts, Material, and Equipment	32	(2)
Shipping and Delivery	34	(5)
Planning Thought Process	39	(15)
Example of a Turnaround Planning Sheet	43	(3)
Applying the Planning Thought Process to Large Jobs	46	(5)
Example of Planning a Large Job	51	(3)
Estimating Tips	54	(4)
Determining Elapsed Time and Job Staffing	56	(1)
Including Time Required by Operations	57	(1)
Work Packages	58	(1)
Contracts for Services	59	(12)
Types of Contracts	59	(2)
Contract Revisions	61	(1)
The Bidding Process	61	(1)
Bidding Requirements	62	(1)
Standard Forms of Construction Contracts	63	(1)
General Provisions of a Construction Contract	63	(6)
Technical Specifications	69	(2)
Reference Standards	71	(1)
Summary	71	(2)
Scheduling the Work	73	(32)
Critical Path Method (CPM)	73	(15)
Logic Network Conventions	74	(2)
Preparing a Logic Network	76	(1)
Finding the Critical Path	76	(3)
Interfering and Free Float	79	(2)
Load Leveling	81	(5)
Project Duration versus Project Cost	86	(2)
Program Evaluation and Review-Technique (PERT)	88	(4)
The Monte Carlo Method	92	(4)
Project Management Software	96	(5)
Choosing the Right Program	97	(2)
Sorting and Communicating Information	99	(1)
Breakdown Structures	100	(1)
Summary	101	(4)
Executing the Project	105	(12)
Shutdown Safety	106	(1)
OSHA Requirements	106	(1)
Developing Daily Schedules	107	(3)
Updating Job Status	110	(1)
Reporting Project Status	111	(1)
Tracking Project Costs	111	(3)
Summary	114	(3)
Reporting and Documenting the Shutdown Activity	117	(14)
Project Review Meeting	117	(2)
Project File	119	(1)
Final Report	119	(1)
Sample Shutdown Report	120	(8)
Safety	121	(1)
Discussion of Major Shutdown Jobs	122	(4)
Comments and Recommendations	126	(2)
Summary	128	(3)
Appendix A Boiler Shutdown Example	131	(14)
Boiler History	132	(2)
The Shutdown	134	(1)
Identifying the Work	134	(3)
Building the Work List	137	(8)
Appendix B Identifying Electrical Work to Be Performed During a Shutdown	145	(18)
Electrical Shutdown Checklist	145	(18)
Months and Weeks Prior to the Shutdown	145	(10)
During the Shutdown	155	(8)
Appendix C Machinery Inspection Prior to and During a Shutdown	163	(50)
Bearing Data	163	(2)
Shaft Alignment Standards	165	(7)
Run-Out Measurements	167	(1)
Alignment Data Conventions and Checks	168	(1)
The Definition of a Line	168	(2)
Off-Zero Alignment	170	(2)
Gear Drive Inspection Standards	172	(6)
Gear Tooth Nomenclature	172	(1)
Gear Maintenance	173	(1)
Gear Drive Backlash	174	(1)
Gear Failure Analysis	175	(3)
V-Belt Drives	178	(4)
Causes of Belt Slip	179	(1)
Incorrect Tension	179	(1)
Sheave Wear and Damage	180	(1)
Alignment	180	(1)
Belt Tensioning	181	(1)
Pumps and Mechanical Seals	182	(21)
System Curves	183	(2)
Pump Characteristic Curves	185	(1)
Combined System and Pump Curves	186	(1)
Pump Affinity Laws	187	(3)
Understanding Cavitation	190	(1)
Determining Pump Condition	191	(1)
Centrifugal Pump Repair	191	(8)
Mechanical Seals	199	(4)
Fans	203	(10)
Fan Laws	203	(2)
Fan Performance Curves	205	(8)
Glossary	213	(6)
Index	219