SystemShutdown, Turnaround & Outage

Turnaround Lessons Learned

Turnaround lessons learned that reads past final reports, joins the same lesson across events, checks whether anything changed, and proposes the exact step on the next plan.

See the demo Book a demo

Follow one lesson from six reports to one step ↓

The problem

Turnaround lessons learned at closeout, and written again next time

At closeout, lessons go into the final report as paragraphs with no tag, no contractor and no step. The action reads use anti-seize, and nobody owns getting it into the job pack.

Next time the pack is copied forward, the studs gall again, and someone writes the same lesson again, worded differently. The register keeps growing while the work stays the same, and by the next post-turnaround review nobody can say which lessons were truly learned.

Built forLessons ownersDiscipline leadsTurnaround plannersContractor superintendentsInternal auditors

The Problem Today

Lessons get written down at each closeout, and the same ones come back because nothing reaches the next plan.

Reread by hand, if at all

Reports
Job packs
Schedules
Contracts

Same lesson, new wordsEach closeout writes it again, so nobody counts repeats
Closed with no proofMarked learned, though the pack never changed

The Solution

Read the final reportsEach lesson cut out with its page, words kept as written
Join the repeatsOne lesson under many wordings, traced across turnarounds
Check what really changedLater packs, schedules and contracts read for the action
Place it on the next planA step proposed; the planner accepts and a lead countersigns

Built-in controls

A lesson counts as learned only with proof
Agents never change a pack or schedule
Planner accepts, a lead countersigns

What You Get

The next turnaround starts with each repeated lesson on the step where it belongs, and proof of what changed.

Repeats countedEach lesson traced across turnarounds and units
Learned means provenClosed only when a later document changed
Lessons on the planProposed on job pack steps, take-offs, lots and activities

Four months before scope freeze

Turnaround lessons learned, from six final reports to two job pack steps

A refinery is planning its next turnaround. The lessons owner wants to know which of the lessons in six past final reports were learned, and which only written down.

demoThe refinery, its crews and every count are sample data.

01Morning
1,887 pages read, and 1,938 lessons cut out with their page
Lessons owner
The report reader cuts each final report into single lessons, each pointing back to its page, and keeps the words as written. The same-lesson matcher, link finder and repeat tracker run behind it. One of the six reports is an uncontrolled photocopy, and the screen says so. Each lesson read from a report shows whether it repeated or was learned.
02Morning
A limit switch wrong at startup, written two ways, one lesson
Lessons owner
The matcher finds one lesson under two wordings: same piping and valves issue, nothing in either wording that points to a second cause. It proposes one lesson at 85%, labelled as a sample figure. The lessons owner agrees or keeps them apart, and another person checks it before it counts. 63 merges wait this way.
03Morning
612 distinct lessons, and 148 that came back and are still open
Lessons owner
The repeat grid puts every lesson on one picture: 14 units down the side, six turnarounds across, circles sized by how many lessons were written. Lines join a lesson each time it returns. The rail ranks what keeps coming back by the hours the reports themselves state: 2,202 on repeats, as the reports put it.
04Morning
Galled channel cover studs: five write-ups, three turnarounds, one action
Lessons owner
Picking the top line lights it across the grid. The studs galled on two exchangers, written up five times at three turnarounds, and each time the action was the same: use anti-seize. The last report is silent, and the screen says a silent report is no proof the problem went away.
05Morning
No change in the pack, the schedule or the take-off
Lessons owner
The proof checker reads what was issued after the lesson. Lines 2 and 6 of the job pack read the same in each later issue, with no anti-seize. The schedule activity still allows the same hours. No spare stud set is on any take-off. One contract lot could not be read, so it says not yet, never no change.
06Morning
Two steps proposed, with anti-seize where the studs are made up
Turnaround planner
The placement agent keeps the pack’s seven lines and proposes detail under two of them: break-out under pulling the bundle, and make-up under reinstalling it, with anti-seize named on the threads. It says the lesson is not acting until both change, and it asks the bolting lead a question it cannot answer itself: is anti-seize enough?
0709:26
The planner accepts, and nothing counts yet
Turnaround planner
The planner accepts the placement with a reason: right step, wording as proposed. Both steps now read accepted, not countersigned. The lesson stays repeated until a discipline lead opens the source and signs. The spare stud set and the hours on the schedule activity are marked as not part of this decision, so they wait for their own owners.
0809:29
The lead opens the source, signs, and the lesson moves to acting
Discipline lead
The discipline lead opens the report pages behind the lesson before the sign button works. Once she countersigns, both steps read now in the plan, and the lesson moves from repeated to acting. It will count as learned only when a later issue of the pack shows the change, read by the proof checker and confirmed by a person.
0909:30
285 open lessons with a proposed place, each on its own clock
Turnaround planner
The plan view sets every proposed placement against the dates that matter before oil out: contract lots, take-offs, the baseline, scope freeze, job packs and the schedule. Each lane has its own clock. Below, each lesson shows where it would land, the agent’s confidence and its status. Every one still waits for a planner.

Galled studs, written up five times, the same action each time

What the final reports say about one lesson, in their own words.

Turnaround	Where	Written	Hours stated
Four back	Hydrocracker exchanger	7 of 44 seized	16
Three back	Hydrocracker exchanger	11 damaged	19
Three back	Coker exchanger	6 galled	8
Two back	Hydrocracker exchanger	Galling again	11
Two back	Coker exchanger	5 replaced	7
The last	Hydrocracker exchanger	Report silent	None stated

demoSample data, from the working solution.

Silent reports, missing take-offs and a contract nobody could open

What the proof checker would not let pass as learned.

A silent report is not a fix

The last report says nothing about the studs, and the job ran with the same pack.

No spare set on any take-off

Studs were replaced each time, yet no take-off since lists a spare stud and nut set.

Hours never moved

The schedule activity for stud work keeps the same allowance through each later issue.

One lot could not be read

An expired system sign-in left one contract unread, so it reads not yet.

demoSample data, from the working solution.

Around the register

The register, links to tags, closeout capture and the baseline before freeze

Six more screens the lessons owner, leads and auditors use.

Shutdown lessons learned database: 612 distinct lessons with tag, times seen, last turnaround, owner desk and status — **Lessons**612 distinct lessons with tag, times seen, last turnaround, owner and status, each with every wording and its sources.

Lessons tied to current tags, with the tag as written in the report and the closest match in the register for a person to link — **Links**Each lesson tied to a tag, a contractor and a scope item. The ones that could not be linked show their words and the closest match for a person.

Closeout lessons capture: four questions asked by the interviewer, and notes from crews waiting for the lessons owner to accept — **Capture at closeout**The interviewer asks four questions while it is fresh, checks for a match, and leaves the notes for the lessons owner.

Queue of turnaround lessons work: disagreements, proof to confirm, merges, links and placements, each with its owner and a due clock — **Queue**Countersigns, disagreements, proof, merges, links and placements, each with its owner and clock.

The lessons baseline for the next turnaround: who owns it, the clock to scope freeze, where it stands and the bulk placement — **The baseline**What the next plan must carry before scope freeze: the planner proposes, a lead checks a sample and signs, the lessons owner owns the list.

Post turnaround review audit trail: reports read, lessons joined, proof checked, placement proposed, accepted and countersigned — **Audit trail**Each agent step and decision, who made it and when, from reading the reports to the countersignature.

demoSample data, from the working solution.

Five roles, and a contractor who sees only his own lot

The person who accepts never countersigns the same placement.

Lessons owner

Sees: The register, the repeats and the proof waiting
Signs: Agrees merges and links, confirms proof

Discipline lead

Sees: The report pages behind each lesson
Signs: Countersigns placements, proof and merges, and settles disagreements

Turnaround planner

Sees: Each proposed place on the plan, with the lesson’s words
Signs: Accepts or rejects placements with a reason

Contractor superintendent

Sees: Lessons on his own lot only
Signs: Answers lessons about his crew

Internal auditor

Sees: Who closed what, and on what evidence
Signs: Reads and exports

The agents

Seven agents cut, join and place lessons, and none closes one

Each stops at the person who decides.

Report reader

Cuts each final report into single lessons with a page.

Never rewrites
Marks unreadable pages

Same-lesson matcher

Finds the same lesson in different words.

Never merges different causes

Link finder

Ties a lesson to a tag, a contract lot and a scope item.

Never links on a guess

Repeat tracker

Joins a lesson across turnarounds.

Never reads a blank square as fixed

Proof checker

Reads later packs, schedules, contracts and take-offs, and quotes what changed.

Never closes a lesson

Placement agent

Proposes the step on the next plan and carries the lesson’s own action.

Never changes a pack, schedule or contract

Closeout interviewer

Takes new lessons by asking four questions, and checks for a match.

Never invents a tag or an hour figure

What planners ask about turnaround lessons learned

What is turnaround lessons learned software?

Turnaround lessons learned software keeps the lessons from past turnarounds and makes sure they change the next one. Here agents read the final reports, join the same lesson across events, check later job packs and schedules for the action, and propose a step on the next plan. A planner accepts and a discipline lead countersigns.

We keep a lessons learned register already. What changes?

A register lists lessons. This also counts how often each came back, shows whether anything changed afterward, and puts the open ones on the next plan’s steps. A lesson counts as learned only when a later document shows the change.

Does it replace the post turnaround review?

No. The review still happens. The closeout interviewer takes lessons while they are fresh, checks them against what is already known, and leaves them for the lessons owner to accept.

Can contractors see the lessons?

A contractor superintendent sees lessons on his own lot only and can answer the ones about his crew.

What does a turnaround post mortem look like here?

Each lesson keeps its wording and page from every report it appears in, the hours the reports state, the proof checker’s findings and every decision on the audit trail.

Do the agents change our job packs?

No. They propose wording and a place. The planner accepts it, a discipline lead countersigns, and the pack itself is changed in your turnaround management system.

Shutdown, Turnaround & Outage

Bring your last six
final reports.

We’ll show you which lessons came back, and the step on your next plan where each one belongs.

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Turnaround Lessons Learned

Turnaround lessons learned at closeout, and written again next time

The Problem Today

The Solution

What You Get

Turnaround lessons learned, from six final reports to two job pack steps

1,887 pages read, and 1,938 lessons cut out with their page

A limit switch wrong at startup, written two ways, one lesson

612 distinct lessons, and 148 that came back and are still open

Galled channel cover studs: five write-ups, three turnarounds, one action

No change in the pack, the schedule or the take-off

Two steps proposed, with anti-seize where the studs are made up

The planner accepts, and nothing counts yet

The lead opens the source, signs, and the lesson moves to acting

285 open lessons with a proposed place, each on its own clock

Galled studs, written up five times, the same action each time

Silent reports, missing take-offs and a contract nobody could open

The register, links to tags, closeout capture and the baseline before freeze

Five roles, and a contractor who sees only his own lot

Seven agents cut, join and place lessons, and none closes one

What planners ask about turnaround lessons learned

More solutions for turnaround planners and leads

Bring your last sixfinal reports.

Bring your last six
final reports.