Plant Shutdown Turnaround And Outages (STO) With Advanced Techniques

Course overview

A shutdown turnaround outage is what? Complex, compact, high-pressure, high-temperature process systems are used in the oil, gas, and chemical industries to handle extremely flammable, explosive, and hazardous fluids and chemicals. Not only should their design be extremely dependable throughout the project phase, but during steady-state operations, their inspection and maintenance should be performed in accordance with the designers’ instructions.

While some plant maintenance tasks, such as condition monitoring, can be completed online while the plant is operating, others necessitate shutting down the plant in order to complete extensive planned maintenance tasks and inspections that will make the plant operational until the next scheduled shutdown. These shutdowns are often scheduled in accordance with risk-based business and safety policies.

Turnaround refers to the maintenance procedures that include internal inspection, repairs, and component replacements when the plant is shut down. This situation is referred to as an outage because the plant is not generating during the stoppage. The turnaround operations must be conducted properly to reduce worker injuries and prevent any incidents that could endanger the asset or the environment. These are the most crucial factors.

Participants in this Training Bee training program will gain in-depth understanding of Plant Shutdown, Turnaround, and Outages (STO) Management, as well as the related Best Practices.

Introduction

To maintain facility maintenance, safety, and efficiency, industrial settings employ crucial procedures and tactics that must be understood through an introduction to Plant Shutdown, Turnaround, and Outages (STO) Management and Best Practices. The goal of this course is to give students the fundamental information and abilities needed for efficient STO management.

Plant shutdowns, turnarounds, and outages (STOs) are scheduled occurrences that are essential to preserving the dependability, integrity, and safety of facilities in the industrial sector. The goal of this introductory course is to give students a thorough grasp of STO management by focusing on best practices and critical competencies needed for organizing, carrying out, and supervising STOs.

We are The Training Bee, a global training and education firm providing services in many countries. We are specialized in capacity building and talent development solutions for individuals and organizations, with our highly customized programs and training sessions.

To sum up, participants receive a thorough grounding in plant shutdown, turnaround, and outage (STO) management as well as best practices, which gives them the tools they need to guarantee the dependable, secure, and effective operation of industrial facilities.

Learning Objectives

Upon completing Plant Shutdown Turnaround and Outages (STO) Management and Best Practices, participants will be able to:

Recognize the principles of Plant Shutdown, Turnaround, and Outages (STO) Management, as well as Recommended Practices.
Understand the distinction between a partial and complete shutdown, as well as the safety risks involved.
Discover the concepts underlying risk-based maintenance and inspection.
Recognize the significance of daily execution meetings and stage-by-stage planning for successful STOs.
Acquire knowledge of the safe shutdown, turnaround, and startup procedures.
Focus on the contractors’ workforce’s safety preparation during the turnaround, as well as the client-contractor relationship that goes along with it.
Recognize safety protocols to get the plant’s pipes and equipment ready for maintenance and inspection.
Receive training on turnaround inspection and maintenance tasks in unique scenarios like as working at heights, underground, underwater, and confined places.

Our Unique Training Methodology

This interactive course comprises the following training methods:

Journaling – This consists of setting a timer and letting your thoughts flow, unedited and unscripted recording events, ideas, and thoughts over a while, related to the topic.
Social learning – Information and expertise exchanged amongst peers via computer-based technologies and interactive conversations including Blogging, instant messaging, and forums for debate in groups.
Project-based learning
Mind mapping and brainstorming – A session will be carried out between participants to uncover unique ideas, thoughts, and opinions having a quality discussion.
Interactive sessions – The course will use informative lectures to introduce key concepts and theories related to the topic.
Presentations – Participants will be presented with multimedia tools such as videos and graphics to enhance learning. These will be delivered engagingly and interactively.

Training Medium

This Plant Shutdown Turnaround and Outages (STO) Management and Best Practices training is designed in a way that it can be delivered face-to-face and virtually.

Course Duration

This training is versatile in its delivery. The training can be delivered as a full-fledged 40-hour training program or a 15- hours crash course covering 5 hours of content each day over 3 days

Pre-course Assessment

Before you enroll in this course all we wanted to know is your exact mindset and your way of thinking.
For that, we have designed this questionnaire attached below.

Why are plant shutdowns, turnarounds, and outages (STOs) necessary in industrial contexts, and what is their main objective?
List at least three essential STO process steps and provide a brief description of each phase’s goals.
In what ways does efficient STO management enhance plant or facility safety, upkeep, and operational effectiveness?
Give a summary of the main difficulties and dangers posed by plant STOs, along with any possible fallout from poor planning and execution.
What does a STO manager or coordinator do, and what abilities and traits are necessary to succeed in this position?
Describe the meaning of the “critical path” in STO planning and how it helps to keep the project on track.

Course Modules

This Plant Shutdown Turnaround and Outages (STO) Management and Best Practices covers the following topics for understanding the essentials of the Agile Workplace:

Module 1 – Ideas for the management of plant shutdowns, turnarounds, and outages (STO)

Definitions, illustrations, and extent of shutdowns, turnarounds, and outages
Complete and partial shutdowns, as well as the safety issues they pose
The daily execution meetings and stage-by-stage planning necessary for effective STOs
Theoretical framework for risk-based maintenance and inspection
Managing STO’s resources (money, materials, and labor)

Module 2 – SAFE END OF DAY FOR THE PLANT

Using standard operating procedures for depressurization
Venting, Draining, and Flushing Valve Isolations and Flange Blinding
Desiccation and Penetration
To prepare for safety, manholes should be opened and equipment should be cleaned.
Granting access for upkeep and internal examination

Module 3 – CONTRACTOR WORKFORCE SAFETY PREP FOR THE TURNAROUND

Contractor orientation and training regarding the client’s environment, health, and safety management system
Contractors’ tools and equipment are inspected for safety and integrity, and their health is screened
The familiarity of contractors with the worksite
Work package-based turnaround job briefings for the workforce
Instruction in emergency response
Creating a risk assessment and hazard identification for the designated turnaround jobs

Module 4 – Examining and maintaining enclosed areas

Confined spaces include deep excavations, pipes, columns, and vessels.
The manhole displays a valid Permit to Work (PTW) for a confined space.
Checking the atmosphere inside the small area on a regular basis, or at least at the beginning of each shift
Constrained space sentry posts at manholes and entrance points outside the restricted area
Identity badges of those working in the restricted area are displayed at a board outside the entrance.

Module 5 – INSPECTION AND MAINTENANCE OF ENERGY-RELATED EQUIPMENT

Energy-related risks include electrical, pneumatic, and mechanical energy
De-energizing machinery using energy
Remove the initial points of energization to avoid unintentional energization.
Put a warning label on the isolation points, such as “don’t energize/people working,” and lock them firmly.
The LOTO (lockout and tagout) procedure’s primary management

Module 6 – ASSESSMENT AND Upkeep AT HEIGHT

Only after making sure that employees have lanyards and fall arrest harnesses may the PTW be issued.
Make sure tackles and tools are fastened securely to avoid them falling on other staff members.
When the risk assessment dictates it, use scaffolding that is approved for safety and appropriateness.
Utilizing cherry-picker trucks and man-baskets supported by cranes to allow personnel to work at heights for brief periods of time

Module 7 – UNLOADING AND LOADING OF THE CATALYST

Give classified trained individuals performing the task particular purpose personal safety equipment (PPE), such as self-contained breathing apparatus (SCBA).
Use nitrogen to passivate the vessel as it opens to prevent the catalyst within from exploding.
Using hoppers, unload the catalyst under regulated circumstances. Then, store the spent, or used, catalyst in drums that are secured, disposing of it in accordance with approved waste management procedures.
Examine and fix the mesh and bed that will hold the new catalyst charge.

Module 8 – Inspection and maintenance of subterranean and submerged areas

Using drawings and tools to locate subterranean services will assist you prevent inadvertently damage them when excavating the ground to create the foundation for new equipment, piping support, etc. during STOs.
Protecting the regions that have been dug to prevent people and vehicles from falling inside
Verify the safe air conditions inside the excavation to prevent worker suffocating or hazardous asphyxia.
It is imperative that certified divers assist trained and competent personnel perform underwater inspections and maintenance.

Post-course Assessment

Participants need to complete an assessment post-course completion so our mentors will get to know their understanding of the course. A mentor will also have interrogative conversations with participants and provide valuable feedback.

Explain the responsibilities of a STO manager or coordinator and list the fundamental abilities and characteristics needed to succeed in this position.
Describe the meaning of the “critical path” in STO planning and how it helps to keep the project on schedule.
What variables affect the decisions made about the scope and priority of maintenance and repair activities during a plant shutdown? Give instances.
Emphasize the significance of stakeholder collaboration and communication during a plant STO, and list the essential parties that must be involved.
Think back on the lessons you learned during this course. Which new ideas or insights did you find most useful, and how do you plan to use them in your personal or professional life?

Lessons Learned

STOs Are Essential and Inevitable: After reading this, participants will understand that STOs are essential to the operation of industrial plants. STOs must be properly designed and carried out in order to preserve equipment integrity, increase safety, and boost operational effectiveness.

The Value of Proactive Planning: Planning ahead is the first step towards effective STO management. Pupils will understand that careful planning is essential to reducing unanticipated problems and downtime during the closure.

Timeliness and the Critical Path: Students will have learned how to recognize and rank the tasks that are necessary to keep the STO on track by focusing on the critical path idea.

Stakeholder Involvement: This section will emphasize the significance of stakeholder communication and involvement. Participants will comprehend the necessity of cooperation between different organizational departments and responsibilities.

Safety is Priority One: During STOs, safety is of the utmost importance. After learning about optimal safety procedures, participants will be able to guarantee that the environment and people are safeguarded throughout the outage.

Contingency planning and Risk Mitigation: Students will have gained knowledge on how to evaluate and reduce the risks connected to STOs. They’ll get the value of having backup plans in case of unforeseen difficulties.

Management of Scope: It’s critical to control the extent of maintenance and repair work. Participants will be able to allocate resources wisely, prioritize projects, and assess the scope.

The importance of continuous improvement in STO processes will have been underlined throughout the training. The significance of post-STO evaluations in identifying areas that require improvement will be understood by students.