REFINERY TURN-AROUNDS AND OUTAGES: INTRODUCTORY MANAGEMENT & CONTROL PRINCIPLES

Transcription

1 COURSE REFINERY TURN-AROUNDS AND OUTAGES: INTRODUCTORY MANAGEMENT & CONTROL January 25-26, 2016 Hyatt Regency Houston Galleria Houston, TX EUCI is authorized by IACET to offer 1.1 CEUs for the course. 1

2 OVERVIEW Shutdowns, turn-arounds, outages (STO), and squats are necessary processes within any refinery. Preparation for a planned shutdown can take years and the process itself requires large technical and financial investments. It is imperative that each person involved has a fundamental understanding of processes, safety considerations, planning procedures, and cost control measures. Join us as we discuss an overview of refinery turn-arounds, shut-downs, outages, and squats. We will review STO safety systems, identify hazard recognition techniques during execution, and identify all of the key resources needed during a shutdown or turn-around. Participants will have the opportunity to develop their own Personal Safety Plan. Our expert instructor will discuss project concept, scope, execution, and budget. He will review the gates and gate control systems and discuss cost estimation processes. Attendees will leave with an understanding of project prioritization, work list lead time, and cost control measures. A lot of details and planning go into a successful turn-around project. This course will identify critical pre- and post-downtime logistics to ensure a smooth process. We will review asset management, purchasing strategies, scheduling requirements, and scheduling tools. We will review cost mitigation techniques. Attendees will have the opportunity to create a work pack, examining the process from start to finish. Finally, success is critical to large-scale refining projects. We will discuss STO performance metrics and how to ensure a successful process. LEARNING OUTCOMES Discuss a brief overview of refinery turn-arounds, shut-downs, outages, and squats Review STO safety systems Develop a Personal Safety Plan Identify hazard recognition techniques during execution Identify key resources needed during a shutdown or turn-around Explain how to set up a Milestone System to address project concept, scope, execution, and budget Review the phases of cost estimation Address work list lead time and project prioritization Discuss cost control measures Describe change management system requirements & design Identify pre and post-downtime logistics to ensure a smooth STO process Discuss scoping work list repair items List scheduling requirements and tools Review asset management and purchasing strategies Explain STO performance metrics Express planned costs vs. current costs Create a work pack WHO SHOULD ATTEND Refinery managers in charge of shut-downs, turn-arounds, outages, and squats Operations personnel for refineries STO contractors Service companies who participate in shut-downs, turn-arounds, outages, and squats Refinery engineers Environmental, health and safety managers Any refinery personnel who participate in STOs 2

3 AGENDA Monday, January 25, :00 8:30 a.m. Registration and Continental Breakfast 8:30 a.m. 5:00 p.m.course Timing 12:00 1:00 p.m. Group Luncheon Overview A brief Processes Overview for Shutdowns, Turn-Arounds, Outages, and Squats Introduction: Cost Management During Planned & Unplanned Refinery Maintenance Safety Systems Safety Leadership o Establishing a Safety Champion Mindset o Important Safety Considerations During Refinery Maintenance Personal Safety Plan o Elements of an Effective Personal Safety Plan o Communicating Personal Safety Plans Hazard Recognition Techniques During Execution o Components of a Hazard Recognition System o Components to Consider Based on Job Complexity Designing Safety Into Early Work Plans o When to Set Up the Safety Program/Organization o Components to Consider Based on Job Complexity Leadership Designing the Leadership Team and Key Contributors Identifying Key Resources o Operations o Planners o Schedulers o Execution Supervisor o Estimating Communicating Job Assignments and Expected Outcomes/Deliverables Components of a Stewardship Process to Track Deliverables 3

4 AGENDA Monday, January 25, 2016 (Continued) Tuesday, January 26, 2016 Milestone System (Looking Ahead & Early Preparation) Lead Time to Setup Leadership Team Gates and Gate Control Processes o Project Concept o Controlling Scope, Execution & Budget o Turn-Around Planning Phases o Cost Estimates Work List Lead Time o Critical Considerations o Task Prioritization Job Planning & Scheduling Lead Time Cost Control Gate Structure & Design Work List Generation, Management & Stewardship o Scope of Tasks o Equipment Tags Change Management System Requirements & Design o Critical Considerations for CMS o Who Signs Off On Additional Work Cost Estimating Requirements & System Design Class Exercises Develop a Site Safety Plan and a Personal Safety Plan Layout a Milestone Plan 8:00 8:30 a.m. Continental Breakfast 8:30 a.m. 12:30 p.m. Course Timing Planning Systems & Strategies Pre- and Post-Downtime Activities o Safety Audits o Logistics - Parking Facilities - Security - Administrative Facilities - Electricity Considerations Scoping Work List Repair Items Designing Work Pack for Job Plans 4

5 AGENDA Tuesday, January 26, 2016 (Continued) Planning Systems & Strategies (Continued) Work Pack Requirements to Feed Schedule o Lead o Lags o Tagging Generating Cost Estimates from Work Packs o Labor o Material Execution Review of Job/Work Packs Scheduling Systems Scheduling Tools & Software Scheduling Requirements Generation of Tracking Data for Monitoring Field Progress 3 Shift Look Ahead Strategy Asset Management & Control Purchasing Strategies Material Storage, Management & Controls Security Practices Performance & Stewardship Metrics S Curve Earned Hours vs. Planned Hours Current Cost vs. Planned Costs Schedule Compliance Class Exercises Work List Components Developing a Work Pack 5

6 INSTRUCTORS Larry Lester / Manager / LLS Advisors Group, Inc. Larry has 32 years of mechanical experience in refineries. He worked on ExxonMobil Second Line Maintenance for half Baytown Refinery (approx 200 workers). In this role, he designed the majority of Maintenance Improvement practices across their refinery and chemical plant. He also acted as Maintenance Improvement Supervisor and Leader across the sites. Additionally, he was the turnaround superintended for ExxonMobil USP. Larry has project management experience, conducting maintenance assessments in England, South America and across the United States. He assisted in designing planner training course for ExxonMobil USP as well as for mechanical first line supervisors and second line supervisors. He has designed several Time on Tools models. Larry has his BS EE from Prairie View University and his MS EE from Stanford University. Gary Dunn / TAR Manager/Mechanical Planner/Trainer / LLS Advisors Group Gary has 34 years of mechanical experience in refineries. He worked as an ExxonMobil Maintenance Planner, First Line Supervisor and equipment repair strategist. He led South Texas and many Baytown, Texas site turnarounds. He has excellent knowledge of fixed equipment, repair techniques, and welding practices. Gary is a mechanical planner training instructor with the ability to improve site maintenance repair strategies. He has his BS degree. Arthur Walters / Manager / LLS Advisors Group Art has over 40 years of mechanical experience in refineries. He was a Mechanical Second Line Supervisor for half Baytown Refinery for ExxonMobil. He has managed the complex s turnaround, major projects, and contract administration groups. In this role, he was responsible for safety and management for all site contractors, numbering over 2,000. Art also managed the ExxonMobil USP LaBarge Turnaround. He was a management representative on grassroot diesel hydrofiner at Baytown site, a $475 million project. He has excellent knowledge of equipment reliability and maintainability practices. 6

7 INSTRUCTIONAL METHODS PowerPoint presentations will be used in this program in addition to videos and example scenarios. PROCEEDINGS The proceedings of the course will be published, and one copy will be distributed to each registrant at the course. REQUIREMENTS FOR SUCCESSFUL COMPLETION OF PROGRAM Participants must sign in/out each day and be in attendance for the entirety of the course to be eligible for continuing education credit. CREDITS EUCI has been accredited as an Authorized Provider by the International Association for Continuing Education and Training (IACET). In obtaining this accreditation, EUCI has demonstrated that it complies with the ANSI/IACET Standard which is recognized internationally as a standard of good practice. As a result of their Authorized Provider status, EUCI is authorized to offer IACET CEUs for its programs that qualify under the ANSI/IACET Standard. EUCI is authorized by IACET to offer 1.1 CEUs for the course. REGISTER 3 SEND 4TH FREE Any organization wishing to send multiple attendees to these conferences may send 1 FREE for every 3 delegates registered. Please note that all registrations must be made at the same time to qualify. EVENT LOCATION A room block has been reserved at the Hyatt Regency Houston Galleria, 2626 Sage Road, Houston, TX 77056, for the nights of January 24-25, 2016 Room rates are $179 single or double, plus applicable tax. Call for reservations and mention the EUCI program to get the group rate. The cutoff date to receive the group rate is December 24, 2015, but as there are a limited number of rooms available at this rate, the room block may close sooner. Please make your reservations early. 7

8 Please make checks payable to: PMA" EVENT LOCATION P: F: PLEASE REGISTER THE FOLLOWING A room block has been reserved at the Hyatt Regency Houston Galleria, 2626 Sage Road, Houston, TX 77056, for the nights of January 24-25, 2016 Room rates are $179 single or double, plus applicable tax. Call for reservations and mention the EUCI program to get the group rate. The cutoff date to receive the group rate is December 24, 2015, but as there are a limited number of rooms available at this rate, the room block may close sooner. Please make your reservations early. REFINERY TURN-AROUNDS AND OUTAGES INTRODUCTORY MANAGEMENT & CONTROL : JANUARY 25-26, 2016: US $1395 EARLY BIRD ON OR BEFORE JANUARY 8, 2016: US $1195 EUCI s Energize Weekly newsletter compiles and reports on the latest news and trends in the energy industry. Newsletter recipients also receive a different, complimentary conference presentation every week on a relevant industry topic. The presentations are selected from a massive library of more than 1,000 current presentations that EUCI has gathered during its 28 years organizing conferences. Sign me up for Energize Weekly. How did you hear about this event? (direct , colleague, speaker(s), etc.) Print Name Job Title Company What name do you prefer on your name badge? Address City State/Province Zip/Postal Code Country Telephone List any dietary or accessibility needs here CREDIT CARD Name on Card Account Number Billing Address Billing City Billing State Billing Zip Code/Postal Code Exp. Date Security Code (last 3 digits on the back of Visa and MC or 4 digits on front of AmEx) OR Enclosed is a check for $ to cover registrations. All cancellations received on or before December 25, 2015, will be subject to a US $195 processing fee. Written cancellations received after this date will create a credit of the tuition (less processing fee) good toward any other EUCI event or publication. This credit will be good for six months. In case of event cancellation, EUCI s liability is limited to refund of the event registration fee only. For more information regarding administrative policies, such as complaints and refunds, please contact our offices at (201) EUCI reserves the right to alter this program without prior notice. 8