Podcast: These 7 steps will ensure an efficient plant turnaround

Executing a successful plant turnaround is no easy feat. It requires meticulous planning, coordination of multiple teams, and the ability to anticipate and overcome unexpected challenges. In this episode of the Great Question: A Manufacturing podcast, New Equipment Digest editor-in-chief Laura Davis discusses seven crucial steps that can help ensure an efficient and effective plant turnaround.

This information was originally written by Mike Aughenbaugh, associate target market manager for Swagelok Company, who shares valuable insights gleaned from years of experience helping chemical plants and refineries navigate these complex projects. Whether you're preparing for an upcoming turnaround or simply want to learn more about best practices in this area, this episode is packed with actionable advice you won't want to miss.

Below is an excerpt from the podcast:

The decision to do a plant turnaround is not one made lightly. Chemical plants and refineries across the globe undergo these challenging projects with the help of hundreds of technicians from multiple vendors working on different parts of the plant at the same time. Whether the work involves maintaining, revamping, or renewing a specific system or an entire plant, coordinating the various disciplines and their efforts can be daunting.

One of the most complicated aspects of a plant turnaround is stopping production completely while the work is being done. Since any system downtime results in lost revenue, most plant owners and operators will want to do the job as quickly as possible without sacrificing quality. Longer-duration turnarounds keep contractors on-site and can add costs and risks to the project.

In larger plants, proper plant turnarounds may require years of foresight and planning because of the enormous investment of time and money. Therefore, making sure the turnaround runs smoothly is essential.

Suppliers are operating differently since 2020, and your procurement process should change to include the following seven steps:

1. Engage early with trusted suppliers

Deciding to engage in a plant turnaround is not a spur-of-the-moment determination. Sometimes, the planning begins years before a vendor steps foot in the plant. The reason for such extensive planning is to anticipate as many scenarios as possible and have contingency plans to deal with them.

To make sure a plant turnaround starts properly, owners should reach out to critical parts and service suppliers early in the planning process. Industrial fluid systems often require highly specific parts and components, which may have extended lead times to acquire. Engaging with component suppliers early can ensure you have the necessary parts on hand for installation.

2. Identify areas of new opportunity

Another reason to engage early with trusted vendors is to identify potential areas where systems can be improved, resulting in higher reliability and better performance. Understanding where these opportunities are before work begins can provide a road map to a successful operation.

Working closely with vendors early on can improve the pre-planning involved in the turnaround and can lead to innovative solutions. Doing so also helps to ensure there's adequate lead time to secure approval from ownership, while also minimizing the chance of running afoul of management of change (MOC) requirements. Finally, vendors will assess your system without preconceived notions of how the system currently works. This “fresh eyes” approach from experts can lead to previously unrealized enhancements.

One possible enhancement might be using pre-engineered and preassembled grab sampling panels. Practically speaking, this approach can improve system performance without fundamentally changing the overall design. Additionally, such preconfigured panels make it easier for technicians to collect necessary samples properly.

3. Be prepared for the unexpected

Though it is impossible to account for every contingency and variable, proper planning allows early identification of solutions for the most common roadblocks in a turnaround. Having potential solutions in place allows the project to proceed more efficiently.

Depending on the size and complexity of the fluid system, it can be beneficial to stock a variety of hoses, valves, and adapters before revamping the entire system. Practically speaking, it could be any system component that needs to be replaced, so having the right components on-site will streamline the replacement process. It means less time waiting for components to arrive from vendors and more time installing on-site parts.

To avoid overstocking components and ending up with unused inventory, some suppliers may offer opportunities to stock temporary or consignment inventory with them to ensure the parts are always available when you need them. If your vendor is willing to set up such a program, you will only pay for the actual parts used instead of paying for unused parts on a shelf.

About the Podcast
Great Question: A Manufacturing Podcast offers news and information for the people who make, store and move things and those who manage and maintain the facilities where that work gets done. Manufacturers from chemical producers to automakers to machine shops can listen for critical insights into the technologies, economic conditions and best practices that can influence how to best run facilities to reach operational excellence.