Audel Managing Shutdowns, Turnarounds, and Outages
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...
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Aimed at facilities managers in a variety of industries (chemical, petroleum, pharmaceutical, etc.) this guide explains how to plan for and manage shutdowns, turnarounds, and outages. Brown takes the reader through each stage of these maintenance procedures, from scheduling through execution and documentation. Included in the appendix are an electrical shutdown checklist and pre-shutdown inspection routines for common machinery and components. The text is based upon material developed by the author for seminars he conducted through the New Standard Institute. Annotation ©2005 Book News, Inc., Portland, OR
About the AuthorxiIntroductionxiiiChapter 1Identifying the Work1Identifying the Work2Reviewing the Maintenance Backlog3Identifying Preliminary Work6Risk Management16Risk Identification16Risk Quantification17Risk Response Development18Risk Response Control19Defining and Limiting the Scope19Defining the Constraints of the Shutdown19Prioritizing the Proposed Work20Preliminary Estimates of Proposed Work21Determining Contract Work24Determining Internal Labor Demands25Job Input Cut-Off Date25Prioritizing Last Minute Requests25Summary26Chapter 2Planning the Work29Planning the Shutdown29The Shutdown Organization30Assigning Responsibility32Parts, Material, and Equipment32Shipping and Delivery34Planning Thought Process39Example of a Turnaround Planning Sheet43Applying the Planning Thought Process to Large Jobs46Example of Planning a Large Job51Estimating Tips54Determining Elapsed Time and Job Staffing56Including Time Required by Operations57Work Packages58Contracts for Services59Types of Contracts59Contract Revisions61The Bidding Process61Bidding Requirements62Standard Forms of Construction Contracts63General Provisions of a Construction Contract63Technical Specifications69Reference Standards71Summary71Chapter 3Scheduling the Work73Critical Path Method (CPM)73Logic Network Conventions74Preparing a Logic Network76Finding the Critical Path76Interfering and Free Float79Load Leveling81Project Duration versus Project Cost86Program Evaluation and Review-Technique (PERT)88The Monte Carlo Method92Project Management Software96Choosing the Right Program97Sorting and Communicating Information99Breakdown Structures100Summary101Chapter 4Executing the Project105Shutdown Safety106OSHA Requirements106Developing Daily Schedules107Updating Job Status110Reporting Project Status111Tracking Project Costs111Summary114Chapter 5Reporting and Documenting the Shutdown Activity117Project Review Meeting117Project File119Final Report119Sample Shutdown Report120Safety121Discussion of Major Shutdown Jobs122Comments and Recommendations126Summary128Appendix ABoiler Shutdown Example131Boiler History132The Shutdown134Identifying the Work134Building the Work List137Appendix BIdentifying Electrical Work to Be Performed During a Shutdown145Electrical Shutdown Checklist145Months and Weeks Prior to the Shutdown145During the Shutdown155Appendix CMachinery Inspection Prior to and During a Shutdown163Bearing Data163Shaft Alignment Standards165Run-Out Measurements167Alignment Data Conventions and Checks168The Definition of a Line168Off-Zero Alignment170Gear Drive Inspection Standards172Gear Tooth Nomenclature172Gear Maintenance173Gear Drive Backlash174Gear Failure Analysis175V-Belt Drives178Causes of Belt Slip179Incorrect Tension179Sheave Wear and Damage180Alignment180Belt Tensioning181Pumps and Mechanical Seals182System Curves183Pump Characteristic Curves185Combined System and Pump Curves186Pump Affinity Laws187Understanding Cavitation190Determining Pump Condition191Centrifugal Pump Repair191Mechanical Seals199Fans203Fan Laws203Fan Performance Curves205Glossary213Index219
