Turnaround Improvement Consulting

Carmagen Turnaround Improvement Programs yield great benefits to critical parts of your plant operation.

As an example of the programs, here's one of our approaches to conducting effective turnarounds (T/As)

• Assess T/A Planning and Execution effectiveness
  • Define parameters to measure T/A performance
  • Identify organizational barriers that exist
  • Establish the incentives for change
  • Pinpoint the procedures that need to be upgraded
• Benchmark the competition
  • Cost and schedule indices
• Run length predictability
  • T/A planning milestones
  • Accuracy in predicting work to be done
  • Critical path optimization
• Establish improvement objectives
  • Develop a T/A milestone plan consistent with Pacesetter practices
  • Define the required organizational and procedural improvements required
  • Set up an action plan to implement T/A planning improvements
  • Conduct follow-up reviews to assess implementation of changes

Follow-up consulting support by Carmagen Engineering, Inc.

Proceeding from an initial assessment of current T/A effectiveness, consisting of a one- to two-week visit by two or three of our consultants for interviews with key personnel, Carmagen can provide additional consulting assistance including the following services:

• Estimate the competitive position
• Review critical organizational procedures. This includes:
  • Management role
  • Plant monitoring inspection and process performance
  • T/A planning procedures
  • Budgeting and work progress assessment
• Define preliminary opportunities for improvement
• Identify highest pay-out organizational and procedural changes
• Work with the client's personnel to develop improvement plans
• Summarize action steps to improve procedures
• Estimate timing and resources needed
• Identify training needs

We can assist with implementing selected improvements including:

• Communication and team building
• Redefining roles/responsibilities
• Developing improved procedures
• Budgeting
• T/A milestone plan
• Planning tools
• Critical path development

Carmagen can also work with you in applying the principles of T/A Excellence to a specific T/A. At key stages during T/A preparation we team with your personnel to implement improvements.

We recommend the following series of consulting visits.

• 15 months prior to the T/A: establish the T/A planning objectives
• Two-day visit by one of our consultants to interview key management and T/A planning personnel
• Define the major work item that requires the shutdown
• Set the expectations on duration and cost for the T/A
• Define the margin lost for each day of lost production
• 12 months prior to the T/A: work list review — to justify the major work activities of the T/A plan
• One-week visit by two or three of our consultants, depending on the nature of the unit and work anticipated
• Review reason for each work activity
• Establish the cost and benefit for work requests
• Conduct justification reviews
• Define work that can be eliminated from the T/A
• Define preparation work to be done by the client
• Preliminary T/A cost estimate
• Identification of personnel responsible for finalizing the work list
• Organization charts for the refinery and the T/A Planning Team
• Consolidated preliminary work lists for the units involved
• Summary of the prior inspection findings for the equipment
• P&IDs showing blocks and by-passes
• Preliminary review of schedule with operations, inspection, and process technical service personnel
• Six months prior to the T/A: work planning review — to analyze the quality of planning and preparation
• One-week visit by two or three of our consultants
• Assess the critical path work execution plan
• Review the T/A execution organization
• Evaluate the contracting approach
• Review the plans for executing the work in a safe manner
• Review materials procurement
• Consolidate the results of work done by the client
• T/A Budget
• Expected Oil-out to Oil-in schedule
• Define work and shift schedules to be used during the T/A
• Prepare preliminary Gantt charts for critical/sub-critical activities
• Summary of the contract development and bid status
• Critical crane lists
• Plans for evaluating work risks
• Summary of delivery of critical materials
• T/A communication plan