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Turnaround Activities
Turnaround Activities
Turnaround Activities
In petroleum refining, turnaround means a scheduled large-scale maintenance activity wherein an entire
process unit is taken off stream for an extended period for comprehensive revamp and renewal. This
operation involves a lot of preparations and requires many precautions, especially during startup.
Collection of all inputs such as previous reports, procurement lead times, job lists, own and contractor
resources availability etc.
Gathering information from the previous turnaround by way of group discussions, reviewing previous
plans and turnaround reports
Finalization of job list and freeze after challenging by experience multi-disciplinary Challenging Team
Prepare an achievable plan and well integrated level I, II, III schedule
Procurement of material
Split between the jobs to be carried out by Company personnel and contractor
Contract Planning
Check the jobs for pre-requisites such as scaffolding, insulation removal, blinds, etc.
Pre-shutdown fabrication
Progressive hand over of the execution portion to the field coordinators, planners, field engineers,
contractor supervisors
Administrative arrangements
Security arrangements
Implementation plans
Turnaround close-out
Keep end blinds /spectacles near line flanges as per positive isolation plans indicating required date for
readiness on tags.
Keep adequate numbers of Testing Spools, temporary Connections for connecting pressure gauges &
drains/vents for testing of Heat Exchangers (Both Shell & Tube side)
Erection of scaffolding wherever possible e.g. For Heat Exchanger, inaccessible Blind locations, control
Valve s, safety valves, etc.
Lifting and shifting arrangement for control valves, Safety Valves, etc.
Provision of Power supply points at planned locations e.g. laying of additional cable if any for welding,
Hydro jetting and Hydro testing M/C.
Preparation of Maintenance Execution Procedure & Work Pack for all S/D Jobs
Preparation of TBRA for all Critical S/D activities e.g. hot jobs, Modification job, work at height or any
other confined space jobs
Assignment of specific job responsibilities to a group of cross functional team e.g. team involving
Maintenance, Operation, Process, Safety and Inspection
Engaging Quality & experienced contractors having good track record of executing S/D Jobs in other
Refineries to the maximum extent.
Use of General & Specific PPE’s e.g. Life line belt, Fall Arrestor
Shutdown office
Resting Place
Cost Estimation of S/D Jobs, Detail technical study and BOM preparation for S/D activities, material
procurement action
Head-Refinery
Construction Coordinator
HSE
Turnaround manager
Turnaround Coordinator
Operation Coordinator
Security
Admin
Commercial
Extra care & constructability review for required lift for fin fan coolers is a must
Contingency plan for temporary lift and scaffolding in CDU / VDU is required
Dehumidification system provided in CDU & VDU column was very effective for maintaining comfortable
atmosphere inside column for workmen, by maintaining temperature between 28 to 32 deg C & Relative
humidity was less than 65% inside the columns. This facility has remarkably contributed in reducing the
time mainly for large quantity of welding and other hot work inside the column.
Exchanger cleaning bay will result time saving by providing central Point for Cleaning of all Tube Bundles
with advance Hydro jetting machines i.e. Inside/Outside Robotic machines and Inspection (Visual & Eddy
Current Testing) was also carried out at same place which helped in good housekeeping and keeping ISBL
unit free from Oil, Coking & Sludge.
Robotic Hydro jetting machine at exchanger cleaning bay is very helpful for Heat Exchangers Tube bundle
cleaning, Machine operating with multi jet nozzles. By applying this method bundle cleaning process was
very fast and effective, and hard deposit removed easily, thus saving time and cost in cleaning of tube
bundles.
Decisive Leadership and problem solving method on spot decisions is a prerequisite skill for team
leaders.
Micro level Turnaround planning shall be started well in advance before 24 months for workforce,
material, machines, job list and its work pack.
Maximizing the pre turnaround activities, bulk material spares, contingency on scaffolding and
consumables will be very helpful for fast turnaround process.
Daily Review and making rolling plan for speedy execution is required.
Optimize the use of Pigging machines in such a way that critical Heater handed over with in minimum
possible durations.
Use of new concepts and modernized gadgets e.g. modern Radiographic machines so that other jobs can
be continued in parallel.
Keep standby manpower for critical activities so that job should not suffer at any cost.