The Basic Building Blocks of a Successful Turnaround

Let's start with the basics.

What are the basic steps, the outline, the path that gets you from A - Z for a Turnaround?

Phase 1: Identification & Strategic Planning - Long Term Strategic Plan 

Your department, business, company, however you define that part of your world where Turnarounds exist, must have a Long Term Strategic Plan that contains a minimum of the following information regarding past and futureTurnarounds:

• Timing
• Frequency
• Duration
• Historical Costs
• Drivers

This typically takes the form of a database.  Data from past turnarounds is listed and used to forecast and populate the info required for future turnarounds.  

The Closure Report from the last Turnaround is reviewed.

This Long Term Strategic Plan is the alert / tickler system for the business in planning, budgeting and allocating manpower for future turnarounds.

A Strategic Management Plan is created and the Core Turnaround Team members named.

Phase 2: Scoping - Turnaround Work List

Simply stated, the Turnaround Work List is the Scope for the Turnaround.

It is the list of jobs that compose the work that will be executed.

This list typically begins with the Work List from the last Turnaround.  

That list is reviewed and combined with jobs from other sources such as:

• Maintenance Work Order jobs designated as Turnaround jobs
• Jobs not done in the last Turnaround
• Reliability items
• EH&S items
• Projects
• Inspections required
• Operations items
• Regulatory Requirements
• HAZOP items

The combined list must be reviewed, prioritized and vetted through a rigorous Risk Assessment and Prioritization Process.

As a minimum, jobs should be prioritized by:

• Must Do
• Should Do
• May Do or Nice to Do

All stakeholders, i.e. representatives from all the sources of jobs that compose the Work List, should be involved in this process.

At the end of this process, the Work List or Turnaround Scope, is approved.... and FROZEN.

Any subsequent work or jobs added to the list must be reviewed and approved by an Add On Process.

A Plan for Management and Control is completed which defines the Work Process and Manpower required to accomplish all the tasks in the next phase.

Phase 3: Detailed Planning and Scheduling

This is the Turnaround Stage or Phase that accomplishes most of the work and documentation related to Scoping, Planning, Cost Estimating and Scheduling the jobs from the Work List.

In addition, the latter part of this Phase delivers the Turnaround Execution Plan, a collection of information, procedures, policies, lists, instructions and communication that enable and guide the thousands of activities that occur during the Turnaround.

Finally, detailed Bid Packages are created and awarded.

This phase concludes with the completion of all preparations to begin the Turnaround.

Phase 4: Execution

In short, this is where the Rubber Meets the Road.

The detailed Job Packages and Schedule created during the Detailed Planning and Scheduling phase are put into action under the guidelines and elements of the Turnaround Execution Plan.

The Execution Phase can be separated into the following major activities:

• Pre-Turnaround Work
• Shutdown of the Facility
• Clearing and Decommissioning
• Execute Turnaround Work
• Commissioning and Startup of the Facility
• Post-Turnaround Work

Phase 5: Close Out

In this phase, the ground work for the success of the next Turnaround is laid.

A Turnaround Review or Critique is conducted to capture learnings, experiences and information from the Turnaround just completed.

This information, the updated Turnaround Work List and Critical Data and Performance Metrics from the Turnaround, are recorded in the Turnaround Closure Report.

This Closure Report becomes the beginning information source for planning the next Turnaround.

There you have it..... a Turnaround simply stated.... but often misunderstood.

If you want to hear more about the preparation for and execution of a successful Turnaround, please give me a call at 979-285-7219 or email me at arhth1@yahoo.com.