“Practical Management for Plant Turnarounds” is a cross industry, easy to follow technical manual for all persons involved in periodic and scheduled maintenance of plant equipment assets and piping systems. The manual addresses the many functional silos of the owner/operator and the different types of contractors: on site, off site, specialty and service.
A Turnaround Management System is required for all periodic and scheduled maintenance, and will greatly assist in forced outages or outages of opportunity. This technical manual provides the reader the necessary practical principles to develop their own in-house turnaround management system.
Scheduled Maintenance, also known as shutdowns, turnarounds and outages, requires a steering committee, a turnaround manager and a turnaround team. The team and turnaround manager determine the budget and length of the turnaround, and then prepare the turnaround procedure.
The Turnaround Procedure consists of five fundamental phases: strategic planning, detail planning, organization, execution and closeout. The technical manual defines the turnaround team’s roles and responsibilities for each phase of the procedure. The phases are presented as discrete elements; however, in actual practice they will overlap.
Master Technical Files are the source for work scope packages and the work scope support systems. The work scope package development and the work scope support systems (support plans) are explained in detail, as they are essential to the efficiency and effectiveness of any plant turnaround.
Waiting for safe work permits, inspections, or materials and poor tool policies are major contributing factors to turnarounds being over budget and behind schedule. By understanding the fundamental principles and impact, and using the examples laid out in the technical manual, policies and procedures can be put in place to increase production and diminish costs.
Practical Management is the ability to successfully move the planning phases to the field for execution.
“The ultimate success of any turnaround is dependant on the person with the wrench in their hand who we must position for success, by standardization and training.” John A. McLay, P. Eng.
"John McLay has, once again raised the bar. The first edition, “Practical Manual for Plant Turnarounds” was, for many years utilized as a building block developing Turnaround frameworks. The newly created second edition reinforces the progressive focus on sustainability through effective Turnaround management. The manual is a new compendium of methodologies, experiences and techniques based on real life participation of more than 200 STO events worldwide."
Mike Grabill, PMP, Turnaround Specialist, BP Americas
I have been in the metal trades for 38 years and known John McLay for 16 of those years.
John's practical approach to maintenance and planning was derived from a long career as a Tradesman, Power Engineer and a Professional Mechanical Engineer working hands on with metal trades personnel during the execution of construction and maintenance projects.
His publication "Practical Management for Plant Turnarounds" coupled with the “Shutdown Checklist” is a common sense approach to organizing work lists and personnel to successfully execute plant shutdowns."
Stephen Droeske, CEO MTL Inspection Group Inc
About John A. McLay
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Published May 10, 2012
by JMC Consulting Ltd.
Business & Economics, Computers & Technology, Science & Math.