Turnaround Management Services
A turnaround is a scheduled event where an entire process unit of an industrial plant (refinery, petrochemical plant, power plant, pulp mill, etc.) is taken off-stream for an extended period of time for repair or renewal. Turnaround is a blanket term that encompasses more specific terms such as inspection & testing, debottlenecking projects, revamps and catalyst regeneration projects.
Turnarounds are expensive in terms of lost production while the processing unit is offline and in terms of direct cost for labor, tools, equipment and materials to execute the project. Turnarounds can affect the company’s bottom line if mismanaged.
PK Technology provides high quality, comprehensive turnaround services and solutions. We use an innovative approach to our turnaround inspection services and planning assessment tools in order to reduce your turnaround cost and keep your turnaround on, or ahead of, schedule. PK is the only contractor that has a digital turnaround tool that provides a pre-turnaround assessment and post-turnaround documentation the minute activities are complete.
We Provide:
- Pre-Turnaround Planning
- Pre-Turnaround Inspections
- Turnaround Execution
- Turnaround QA/QC
- Post-Turnaround Documentation
Turnaround Assessment
What are a plant's turnaround goals?
- A safely executed turnaround
- No environmental incidents
- The work is completed on schedule
- The work is completed within budget
- A quality work effort
- Long-term equipment reliability
Then why do approximately 80% of executed turnarounds fail to deliver one or more of these elements that organizations define as a successful outcome?
Here are a few answers:
- The effort is “oil to oil” NOT “blinds to blinds”
- Conflict between daily work tasks and long-term strategic efforts
- The job of turnaround manager is not a part-time job
- Understanding complexity with limited experience
- Failure to learn from past mistakes
- Lack of inter-departmental involvement (Operations, Inspection, Maintenance, Safety, etc.)
- Capital and maintenance must be a singular event
A STATEMENT HEARD AMONG TURNAROUND PROFESSIONALS
"For a turnaround you get to pick two of the three: on budget, on schedule or quality workmanship."
This statement, while believed by many, is false!
You can have all three plus job safety, an environmentally sound effort and an outcome that will deliver long term plant reliability!
The question is how?
The Turnaround Assessment Cycle
T-24
Initial Effort
This assessment is conducted at the very beginning of turnaround planning. It is designed to assure that a team has been assembled and there are work assignments made to develop documentation that will direct the remaining effort prior to and during execution. The assessment is also designed to assure that the team understands what is required to assemble the turnaround work scope.
T-18 to t-14
Planning
The assessment at this point in time deals with the development and completion of the detailed documentation which will support the following two stages. This assessment is also checking the development of the turnaround work scope assuring that work items are properly vetted for inclusion.
T-11 to t-9
Application
At this level, the assessment addresses the status of the preparation activity associated with the categories and subcategories within the developed documentation. Once again there is a detailed check on the status of the work scope which should be almost to the point of “scope freeze.”
T-4 to t-2
Pre-execution
This is the final and last assessment before the actual execution of the work. In this assessment, all the details need to be in place or completed within a short period of time. Significant gaps identified here have the potential, if not corrected, to have a negative impact on the execution effort.
T-1
Post Audit
Following a turnaround, it is imperative to conduct a lessons learned review by a third party. This effort is designed to identify things that went well so that they can be repeated at the next turnaround. It is also designed to identify opportunities for improvement so that these issues can be corrected the next time. Internal efforts of this sort can suffer due to individual or group bias and should be avoided. Without a post-execution review, there will be no value added to future turnarounds since the information will be lost.
Why Use PK Technology
The most comprehensive digital turnaround assessment tool available
Flexible approach to the assessment process
- Internal peer review without support
- Internal peer review with third party facilitator
- Third-party industry experts to facilitate and provide input / opinion
Turnaround Assessment Topics
- General Logistics
- Strategy
- Outage Preparation
- Staffing
- Safety
- Security and Transportation
- Industrial Hygiene
- Environmental
- Process Safety Management
- Contracts and Contractors
- Outages and Their Capital Projects
- Cost Control
- Inspection
- Procurement of Material
- Materials Management
- Shops Repairs
- Communication Including Radios
- Information Technology
- Training
- Documentation
- Operations (also called Production)
- Scope Related Logistics
- Outage Planning
- Outage Preparation
- Staging
- Transition
- Execution – Effectiveness and Efficiency
Support - Meetings
- Testing, Final Inspection and Approval
- Housekeeping
- Post Outage
- Miscellaneous Logistical
- Components
- Forms
- Other Miscellaneous Items