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Turnaround Equipment History Search

Equipment history search that lays six past turnarounds on one line for any tag, follows its old names, and says plainly what a silent year can and cannot mean.

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Follow one exchanger through six turnarounds ↓
The problem

Equipment history search by today’s tag drops years filed under the old one

A planner building a job pack asks whoever was there last time, then searches the maintenance system by today’s tag and reads short work order text. Old job packs, inspection reports and cost close-outs sit in different places, opened file by file.

When a tag was renumbered, its earlier years drop out of the search. And a year with nothing on file reads as clean, though it may mean nobody opened the equipment, or that the paper is lost. Those are opposite messages for the person writing the next pack.

Built forTurnaround plannersReliability engineersInspection engineersRecords stewardsInternal auditors

The Problem Today

Equipment history lives in people’s heads and in files nobody opens, and a gap in the record reads as clean.

16,000
hours a year if 200 people save two a week for 40 weeks our estimate

Searched by hand today

  • Job packs
  • Inspections
  • Close-outs
  • Work orders
  • Old names drop outA renumbered tag loses its earlier turnarounds
  • Silence looks like cleanNot opened and paper lost read the same

The Solution

  1. Ask in plain wordsThe question is read as a tag, a job and a span of turnarounds
  2. Old names followedRetagging registers join earlier names to today’s equipment
  3. Each turnaround on one lineDone, found, hours and spent, each with its page
  4. Silent years explainedWhat was searched is listed; a person decides what it means

Built-in controls

  • A second person confirms each carried fact
  • Records change only with two names
  • Answers resting on retired records say so

What You Get

Planners start each job pack from what was done, found and spent last time, with the source one click away.

  • Six turnarounds on one lineFor any tag, under every name it carried
  • Silent years namedSearched and not found, or lists missing
  • Facts carried with sourcesInto the job pack after a second person confirms
A week after scope freeze

Turnaround history search for one exchanger, from question to job pack

A planner is writing the job pack for the hydrocracker’s reactor effluent exchanger, a week after scope freeze. It has 1,180 tubes, six past turnarounds and an old tag from before the plant renumbered.

demoThe refinery, the people and every value on the line are sample data.

  1. 01Morning

    Opened 5 of 6, 8,510 hours, $1,279,000 known

    Turnaround planner

    The planner asks what was found the last three times the exchanger was opened. Seven agents read the question, follow the old name, search the records and write the answer with numbered sources. Six turnarounds fill one line: what was done, found, hours and spent each time. One year shows no record of an opening, and one cost is marked as resting on a retired record.

  2. 02Morning

    7 more tubes plugged for pitting at the outlet ends, 19 in all

    Turnaround planner

    Each number opens the page it was read from. The inspection report from the turnaround before last shows the thinnest wall left in service, 0.072 in, against a 0.060 in retirement limit, and pitting at the outlet ends with the cause not stated. The result line is lit on the page, with the inspector’s name and record number.

  3. 03Morning

    480 extra hours between two openings, and where they went

    Reliability engineer

    Comparing two openings side by side shows the hours rising from 1,640 to 2,120. Cleaning salt deposit took 212 of the extra hours, extra inspection at the outlet ends 164, plugging and retest 93, and galled channel cover studs 11. The wall trend sits beside it, marked as arithmetic that nobody has measured.

  4. 04Morning

    No record of an opening found, and five lists that say why

    Turnaround planner

    For the earliest turnaround the line is silent, so the screen shows what was searched. The unit was down that spring. The final worklist, work order index, inspection index, blind list and crane lift log were searched under both names, and none lists it. One invoice line with no tag stays a loose end. It stays that way until a reliability engineer concludes and an inspection engineer agrees.

  5. 05Morning

    The crane lift log for that unit, four bundles and none of them this one

    Turnaround planner

    Each list opens as it is on file, here the crane lift log for that unit, marked as a retired record. The search for both names sits above the page. The panel beside it says what this search cannot rule out: a channel cover can come off and tubes can be tested in place without a lift.

  6. 06Morning

    Lists missing for a pump: nothing can be said either way

    Turnaround planner

    A different silence on a boiler feedwater pump. Every document under its old and new names was searched, and none comes from that year: the unit’s final worklist and work order index are not on file. The screen will not call it opened or not opened. The records steward can be asked to search for the paper.

  7. 07Morning

    Two facts, each with its sources, carried toward the job pack

    Turnaround planner

    The planner picks what the next pack needs: plugged tubes reached 19 and then 27 of 1,180, with pitting at the outlet ends; and the job took 2,120 hours, 11 of them on galled channel cover studs. Nothing lands in the draft until a reliability engineer confirms each fact against its sources.

  8. 08Morning

    Both facts confirmed after he opens each source himself

    Reliability engineer

    The reliability engineer opens the sources behind each fact, then confirms. Only then do both notes land in the job pack draft as history notes, with the note numbers and who carried and confirmed them. A note is a fact with its source, never a scope decision, and the planner keeps building the pack in the turnaround management system.

  9. 09Afternoon

    263 proposed joins of old tags to today’s equipment, and a sample of 12

    Inspection engineer

    A wrong join mixes two machines’ histories, so this is the largest decision on the screens. The batch lists each old name, today’s tag, the match and its evidence, such as a nameplate serial or a retagging register page. The inspection engineer must open a random 12 herself; only her own opens count, and the rest follow only if the sample holds.

One exchanger, six turnarounds, and what the record holds

The line the planner reads, as it stands before any correction.

TurnaroundWhat was donePlugged, running totalHours
Six backNo record of an opening foundNoneNone
Five back, under the old tagBundle pulled, all tubes eddy current tested31,180
Four backBundle pulled; studs galled61,310
Three backBundle pulled, all open tubes tested121,640
Two backBundle pulled; pitting at the outlet ends192,120
The lastBundle pulled, all open tubes tested272,260

demoSample data, from the working solution.

Around the line

Silent years by kind, a unit’s tags, the archive and two-name corrections

Six more screens planners, records stewards and auditors use.

Silent yearsEach turnaround’s possible openings split into opened, searched with no record, and lists missing, with who is chasing the paper.
Across tagsTags on the unit, each with its line of openings where the sample holds one, how many were opened, and the hours.
One openingDone, found, hours, spent, inspector and contractor lot for one turnaround, beside the report it came from.
ArchiveRetired records still answer, with a mark, and any can be asked back by the records steward.
CorrectionsA wrong value is drafted by the records steward and checked by the inspection engineer; the old value stays on file.
Audit trailEach question, answer, carried fact, confirmation and correction, with who did it and when.

demoSample data, from the working solution.

What a gap means is a reliability engineer’s call

Agents read and cite. Engineers and the records steward decide what a gap means and what changes.

No agent concludes a silent yearThe silence checker lists what was searched. A reliability engineer concludes, and an inspection engineer agrees.
Old tags join only above the lineBelow the confidence line, or when two machines fit, the join waits for the records steward.
A blank stays blankThe opening reader never estimates hours or cost that the record does not hold.
A record changes with two namesThe records steward drafts a correction, the inspection engineer checks it, and the old value stays on file.
Notes are facts, not scopeA carried fact goes into the pack only after a second person confirms it, and decides nothing about the job.
The agents

Seven agents search six turnarounds, and none fills a gap

Each one hands to the next, or to the person who decides.

Question reader

Works out the tag, unit, job and years a question means.

  • Never guesses a tag
  • Asks back when two fit
Tag tracer

Follows old names through retagging registers.

  • Never joins two tags below the line
Record finder

Searches the document estate by name, year and type.

  • Read only
Opening reader

Reads done, found, hours and spent, each tied to its page.

  • Never estimates a value
Silence checker

Lists what was searched for a silent year.

  • Never concludes
  • Never smooths a gap
Archive marker

Marks values that rest on retired records.

  • Never hides a mark
Answer writer

Writes the plain answer with every statement cited.

  • Never changes a record

What planners ask about equipment history search

What is equipment history search for turnarounds?

Equipment history search answers what was done, found and spent on a tag in past turnarounds. Here a planner asks in plain words, agents follow the tag’s old names through the records, and the answer lays each past turnaround on one line, each value tied to the page it came from.

We already search the maintenance system by tag. What does this add?

A maintenance system search finds work orders under today’s tag. This reads job packs, inspection reports and cost close-outs too, follows old names from retagging registers, and shows the years a plain search would miss.

What does no record of an opening found mean?

It means the unit’s lists on file were searched under every name the tag carried, and none lists it. The screen shows what was searched and what that search cannot rule out. A reliability engineer decides what it means, and an inspection engineer agrees.

What if the old records are missing?

Then the screen says the lists for that unit and year are not on file, and nothing can be said either way. The records steward can be asked to look for the paper.

Can a planner put the history straight into the job pack?

The planner carries facts, each with its sources. A reliability engineer opens those sources and confirms before they land in the job pack draft as history notes.

Can it serve as a turnaround knowledge base for the whole site?

It reads the same records for every tag, so any tag on any unit gets its line. Answers resting on retired records are marked, and wrong records are corrected by two people with the old value kept.

Shutdown, Turnaround & Outage

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Pick one tag
you are planning this year.

We’ll lay its past turnarounds on one line and show you what each silent year really holds.

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