Challenge

A senior member of Valdes Architecture & Engineering staff was retained as a contractor to act as the main Turnaround (TAR) Manager for the planning and execution of a 750,000-manhour major turnaround at a process facility. The focus was on minimizing downtime, optimizing resource coordination, and achieving all maintenance, inspection, and upgrade goals. Turnaround management enhances asset reliability, extends equipment life, and supports long-term operational performance.

Solution

A Turnaround Steering Team was put in place, designating the TAR Manager as the team leader and the site Operations Manager as the executive sponsor. The Steering Team developed and communicated the premise document and the TAR objectives, which included safety, quality, schedule, and cost, in that order.

The Steering Team also developed a safety plan that included metrics for tracking progress. They focused on engaging the staff by placing motivational safety posters along the TAR walkways, which featured metrics and pictures of some of the site employees' family members.

Additionally, they implemented a project aimed at reducing the risk of slips and falls by enhancing the physical condition and lighting of the TAR walkways and other work areas, including the workshop.

Milestones for the three-year preparation period were developed, communicated, and achieved - from setting up the long-range strategy and concept, to the planning, pre-shutdown phase, inspection and repairs during execution, and the post-execution phase.

Support was also provided for the documentation and dissemination of key lessons learned to drive continuous improvement and knowledge sharing.

Impact

This major TAR was executed without safety, environmental or quality incidents. Oil out to oil in duration was a day ahead of schedule and was 2% below the budgeted cost.

Services

Maintenance, Reliability & Asset Integrity