Turnaround Preparation, Planning, Execution and Review Process

Phase 1Review Long Range

Business Plan & Schedule

Phase 2Prepare the Turnaround Criteria &

Deliverables

Phase 3Develop the Turnaround Work Scope

Phase 4Complete All Turnaround

Planning

Phase 5Complete

Pre-TurnaroundWork

Phase 6Execute theTurnaround

Phase 7Complete Post

TurnaroundDocumentation

& Review

DELIVERABLES & DOCUMENTS• Post Turnaround cleanup of unit and staging areas• Final Report / Metrics• Starting place for next Turnaround

–Preliminary repair and replace work list–Action items and owners–Meeting schedule for next Turnaround

• Audit ReportFOCUS AREAS• Demobilize contractors• Resolve excess materials • Communicate lessons learned• Publish recommendations for future Turnarounds• Update inspection & repair history• Update Turnaround history database• Complete post-Turnaround MOC requirements• Complete APN review• Stakeholder communicationsTOOLS & PROCESSES• Decision making process• Problem solving process• Meeting & communication process• RBI process• Peer Review / Results and Lessons Learned• APN Review• Scheduling & planning software P3• Turnaround Process Checklist• Stakeholder Communication PlanTIMING, PERFORM PHASE 7 REVIEW• 3 Month Post Turnaround

Endorser:•President, RefiningDecision Executive:•Vice President, Refinery ManagerDecision Review Board:•Maintenance Manager, Operations Director, Planning & Economics Director

Will scope meet long

range plan?

Is the execution

plan complete?Will plan

meet short range plan?

Is plant and off-

plot ready?

Is plant on-test?Deliverables

met?

Arethe

deliverables complete and adequate?

Are resources adequate?

Are the plans

competitive?

DELIVERABLES & DOCUMENTS• Training plan• Field mobilization and logistics plan• All pre-work complete• Schedule and cost reports readyFOCUS AREAS• Train operators, mechanics, supervisors

–Work scope–Procedures

• Train for contractors–Safety–Maintenance specifications

• Mobilize execution team• Set up safety, health, environmental requirements• Complete MOC requirements• Install temporary connections for cleanup• Hang all tags• Stage tools, blinds and materials• Begin cost tracking and reporting• Stakeholder CommunicationTOOLS & PROCESSES• Decision making process• Problem solving process• Meeting & communication process• Turnaround execution plan• Scheduling & planning software - P3• Additional Work Control Process• Turnaround Process Checklist• Stakeholder Communication PlanTIMING, PHASE 5 COMPLETED• Feed pulled

DELIVERABLES & DOCUMENTS• Execute turnaround per plan and schedule• Pre start up safety review complete• Daily schedule and cost reports• Lessons learned captured FOCUS AREAS• Conduct safety audits• Hold daily Turnaround meetings• Monitor schedule float and critical path• Prepare plan for next shift• Finish inspection in 1st third of turnaround• Monitor cost tracking and reporting• Review and document MOCs• Review and process additional work• Document all repairs• Manage QA / QC• Manage inter-plant coordination & communication• Stakeholder CommunicationTOOLS & PROCESSES• Decision making process• Problem solving process• Meeting & communication process• Quick MOC process• Turnaround Execution Plan• Scheduling & planning software• Additional Work Control Process• Risk Mitigation/Contingency Plan• Turnaround Process Checklist• Stakeholder Communication PlanTIMING, PHASE 6 COMPLETE• Feed in

DELIVERABLES & DOCUMENTS• All Work Instructions, Lists and Procedures• Final Execution Plan

–Organization Chart–Contracting Plan–Inspection Plan (1st Third)–Safety Plan–Environmental Plan–Facilities Plan–Operating Procedures–Tank and Line Plan–Critical-Path, Manpower-Loaded &

Leveled Schedule with operations–Completed Phase 4 Estimate–Risk Assessment & Mitigation/Contingency

plan–Communication Plan

• Final Approved AFE • APN or Peer Review ReportFOCUS AREAS• Complete shutdown & cleanup plan• Complete commissioning and startup plan• Complete work orders, lists and procedures• Constructability reviews• Stakeholder CommunicationTOOLS & PROCESSES• Decision making process• Problem solving process• Meeting & communication process• Schedule Software• Addition Work Control Process• Work Order, List and Procedure Completion Rate• Peer Review / Critical Path Challenge• Self- turnaround review or APN Tools• Turnaround Process Checklist• Stakeholder Communication PlanTIMING, PHASE 4 COMPLETED• 4 Months Prior to Turnaround

DELIVERABLES & DOCUMENTS• Frozen Work List• Planning-Resource Forecast• Preliminary Execution Plan

– Contracting Strategy– Labor Loading Estimate– Safety Plan– Environmental Plan– Facilities Plan– Operating Procedures– Phase 3 Estimate and Schedule

• Procurement Plan• Planning Schedule• Peer Review / Scope Review Report FOCUS AREAS• Finalize all inputs

– APN review data– On stream inspections– Incidents– Worst actors– Inspection History– Maintenance Backlog– RBI Study– Safety / Environmental– Capital Plan– Turnaround History

• Eliminate all non-turnaround work• Evaluate key plant reliability concerns• Stakeholder CommunicationTOOLS & PROCESSES • Decision making process• Problem solving process• Meeting & communication process• Turnaround philosophy document and criteria

to Screen Potential Work Items• Peer Review / Scope Review• Self review or use APN Tools• Turnaround Process Checklist• Stakeholder Communication PlanTIMING, PHASE 3 COMPLETED• 12 Months Prior to Turnaround

DELIVERABLES & DOCUMENTS• Core Team• Turnaround Philosophy• List of Stakeholders• Stakeholder Communication Plan• Turnaround Planning Milestone Schedule• Preliminary Planning-Resource Forecast • Preliminary AFEFOCUS AREAS• Dedicate resources• Define value of plant downtime• Determine Solomon targets• Define work list criteria • Review of Turnaround history & lessons learned• Define interval and limits• Complete On-Stream-Inspection• Perform RBI study• Stakeholder CommunicationTOOLS & PROCESSES• Decision making process• Problem solving process• Meeting & communication process• Change management process• Turnaround Planning Process Overview• Define roles & responsibilities• Input checklist• Solomon RAM Tables• Inspection Records• Computerized Maintenance Management

System• Long Range Turnaround & Capital Plans • Incidents & Worst Actor Equipment• RBI Process• Turnaround Process Checklist • Lessons learned / Final Report from Last

Turnaround• APN Tool SetTIMING, PHASE 2 COMPLETED• 24 - 15 Months Prior to Turnaround

DELIVERABLES & DOCUMENTS• Short Range Turnaround Schedule• Long Range Turnaround Schedule• Short and Long Range Budgets (Phase 1

Estimates)FOCUS AREAS• Determine local and national mechanical labor

force limits• Review policies and regulations impacting

turnaround requirements– API/Boiler Codes/Laws & Regulations / RBI

• Review Unit Performance vs. Benchmarks– Intensive Process Review– Yield / Energy / Reliability / OPEX– Turnaround interval / Cost /Duration– Interval Limits

• Determine Capital Requirements– Environmental Compliance– Market Needs– Technology Gaps– Reliability Improvements

• Plan to Minimize Lost Profit Opportunities– Value of Downtime– De – cluster the Turnarounds– Coordination with San Antonio– Market Conditions and Changes

TOOLS & PROCESSES• Decision making process• Problem solving process• Meeting & communication process• Solomon Study• Business Plan• API / Boiler Codes / Company Specs• Plant Inspection Plans• Intensive Process Review

• Lessons learned / Final Report from Last Turnaround

• Turnaround Process Checklist• Long Range Capital Plans• APN Tool SetTIMING – PHASE 1• On-going, part of annual planning cycle

•Core Team•Planning schedule•Opportunity & framing document•Planning and labor forecast•Stakeholder communication plan

•Long Range Turnaround Schedules•Budgets •Short range plan

•Frozen work list•Planning & labor forecast•Prelim. execution plan•Planning schedule•Procurement plan•Audit report

•Final execution plan•WOs, Lists, procedures•Final AFE•Audit Report

•Training plan•Schedule & cost reports•Field mobilization•Pre-work

•Execute as planned•Schedule reports•Cost reports•Lessons learned•Pre Startup Safety Review

•Clean plant•Final reports•Plan for next Turnaround•Audit report

Team Leader: Planning & Economics Director

Team:•Turnaround Manager•Project Engineering Manager•Operations Director•Reliability Manager

Team Leader: Turnaround Project Manager

Team:•Operating Representative•Reliability Representative, Inspection•Design Engineer•Process Engineer•Capital Project Manager•Maintenance Representative

Team Leaders: Turnaround Operations Coordinator & Maintenance Supervisor

Team:•Operators•Mechanics•Engineers•Inspectors•Contractors

Endorser:•Refinery ManagerDecision Executive:•Operations Director Decision Review Board:•Complex Manager, Turnaround Manager, Engineering Director, Planning & Economics Director, Reliability Manager, Project Engineering Manager

Endorser:•Operations DirectorDecision Executive:•Operating Complex Manager Decision Review Board:•Planning Engineer, Turnaround Manager, Project Engineering Manager, Reliability Manager

Endorser:•Operations DirectorDecision Executive:•Operating Complex Manager Decision Review Board:•Planning Engineer, Turnaround Manager, Project Engineering Manager, Reliability Manager

Endorser:•Operations DirectorDecision Executive:•Turnaround Project ManagerDecision Review Board:•Turnaround Core Team

Endorser:•Operations DirectorDecision Executive:•Turnaround Project ManagerDecision Review Board:•Turnaround Core Team

Endorser:•Operations DirectorDecision Executive:•Operations Complex Manager Decision Review Board:•Maintenance Director, Planning Engineer, Turnaround Manager, Project Engineering Manager, Reliability Manager

Team Leader: Turnaround Project Manager

Team:•Operating Representative•Reliability Representative, Inspection•Designs Engineer•Process Engineer•Capital Project Representative•Maintenance Representative•Contractor Representative

Team Leader: Turnaround Project Manager

Team:•Operating Representative•Reliability Representative , Inspection•Designs & Process Engineer (1 each)•Capital Project Representative•Maintenance Representative•Contractor Representative

Team Leaders: Maintenance Supervisor & Turnaround Operations Coordinator

Team:•Operators•Mechanics•Engineers•Inspectors•Contractors

Team Leader: Turnaround Project Manager

Team:•Operating Representative•Reliability Representative, Inspection•Designs Engineer•Process Engineer•Capital Project Representative•Maintenance Representative

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Return to Phase 1

TurnaroundCloseout

Complete?From Phase 7

StartHere

No No No No No No