Facilities can reduce costs by developing real-time asset strategies during turnarounds. Turnarounds allow facilities to make major repairs, perform inspections, and implement crucial unit replacements or adjustments to offline equipment. While turnarounds are costly to perform, there are a few cost-reduction opportunities facilities can utilize to ensure they fully benefit from their turnarounds.

On average, facilities waste up to 60% of their costs on evergreening asset strategies after the completion of a turnaround. Post-turnaround tasks such as processing and analyzing data and managing risks require a significant amount of time and resources. Additionally, the intricacies of a turnaround can cause miscommunication among various teams after the unit or facility starts back up, which can lead to duplicated work effort and unnecessary costs. Creating real-time asset strategies during turnarounds can help facilities optimize their inspection strategies to reduce the budget and resources for post-turnaround tasks.

While many facilities may reduce costs as a result of developing real-time asset strategies during turnarounds, facilities that struggle to maintain evergreening strategies after the completion of a turnaround or facilities that do not have a strong turnaround scope of work defined prior to startup will benefit the most from implementing this cost-savings strategy. In addition, facilities that continue to experience failures or other incidents caused by missing data should leverage this approach as well.

Before implementing any cost-savings initiative, facility management should first evaluate the current state of their facility:

Are you modifying turnaround scopes within 30 days prior to turnaround?

Are you managing your turnaround process holistically (planning 12-18 months in advance) or are you modifying your plans closer to the turnaround (planning within 6-12 months)?

Are you managing your turnaround data digitally?

Are you leveraging current industry tools to execute your turnarounds or are you still utilizing Excel and paper documentation?

Do you have strategies that identify asset-specific work scopes and do those strategies translate to successful executions?

If you don’t have strategies that identify specific work scopes that you’re going to perform on a specific asset, what does your current state look like?

Are you able to quantify the value of your turnaround efforts?

Inspections are often performed from a compliance standpoint, but are you able to quantify the reduction of your facility’s risk or value your facility will receive from conducting a specific inspection?

After determining the current state of their facility, management can develop a tailored plan to create real-time asset strategies during their next turnaround. To realize the greatest savings in costs, facility leaders should:

    • Ensure work processes are digitized and Equipment Asset Reliability Assessment (ARA) is complete
    • Define detailed turnaround scope
    • Define team responsibilities to support data management and engineering analysis throughout the turnaround
    • Assess and deliver quantified value of turnaround activities prior to and following startup

Digitizing work processes ensures facility personnel has access to accurate, up-to-date information. All processes and documentation affiliated with critical turnaround scope items should be digitized and readily available to field personnel. These documents include piping and instrumentation diagrams (P&IDs), isometrics, construction data, and process design information. For more information on how to digitize processes, read our blog, Reduce Cost by Digitizing Your Work Processes.

Defining detailed scope requirements prior to turnarounds will help facilities optimize their inspection plans prior to an upcoming turnaround. Facilities can identify areas to optimize their inspection plans by focusing on the key systems of their assets. For example, if a facility currently uses a time-based interval to drive the inspections for one of its towers, it may have the opportunity to optimize its strategy by reducing the number of corrosion monitoring locations (CMLs) inspected. Additional scope requirements that will help facilities optimize their inspection plans prior to turnarounds include:

    • Organizing associated documents and drawings to ensure field personnel has access to the most updated information
    • Defining susceptible locations
    • Coordinating maintenance activities with the inspection plan
    • Defining inspection technique and threshold for each CML
    • Prioritizing activities by area

Additionally, facility management needs to ensure they have clearly defined the roles and responsibilities for their teams during the turnaround. Knowing who is responsible for executing the inspection and maintenance activities as well as who is responsible for managing and updating the asset strategies during the turnaround is crucial to having a successful turnaround.

Finally, facilities should have a clear understanding of the current risks and the health of their assets prior to their upcoming turnaround. Identifying the acceptable range for asset health post-turnaround will help facilities quantify the impact the turnaround tasks had after the turnaround is completed.

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