WorkflowShutdown, Turnaround & Outage

Turnaround Work Package Planning

Turnaround work package planning that drafts each job pack from past packs and standards, cites every step, and shows the planner only the steps that moved.

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Follow one job pack from draft to the walk ↓

The problem

A turnaround work package copied forward, old rigging and all

A planner opens last turnaround’s job pack, changes the date and sends it on. Old tags, old methods and old rigging come along, and the page looks finished. Packs get written at a desk, weeks before anyone stands on the pad.

Meanwhile a pipe rack has gone up across the crane pad, a plant change has added a blind the list never had, and the stud lesson has been written in three final reports without reaching a single step. The signer reads the whole pack and cannot see what moved.

Built forTurnaround plannersLead turnaround engineersContractor plannersField walk coordinatorsAudit and assurance

The Problem Today

Job packs get copied from last time, so old methods ride along on a page that looks finished.

18.8K: planner hours an event, at six hours saved on each job pack our estimate

Checked by hand today

Past packs
Changes
Lessons
Hours

Copied, not checkedOld tags and rigging carried into a new pack
The signer sees everythingAnd so cannot see which steps moved

The Solution

Drafted from past packsEach step carried across with crew, hours and one source
Stale steps flaggedSteps tested against plant changes, drawings and standards
Lessons on the stepA lesson lands on the step it affects, with its citation
A person on each changeThe planner decides each change; the pack is walked, then signed

Built-in controls

The planner decides every changed step
No step is written without a source
Nobody signs their own pack

What You Get

Planners spend their hours on the steps that moved, and every pack issues with a source behind each line.

Stale steps caughtBefore a crew meets them on the pad
Lessons that change packsPlaced on the step, with the hours they cost
A signature on what movedThe checker opens each changed step first

One job pack, six months before oil out

A turnaround work package for one exchanger, the steps that moved

Oil out is about six months away, and 3,126 job packs are needed. This one, a critical pack, covers a reactor effluent exchanger on the hydrocracker. The agents draft it from the last three packs, whose wording never changed.

demoThe exchanger, the crew, the pads and the hours are sample data.

01Morning
38 steps from three past packs: 31 kept, 5 changed, 2 stale
Turnaround planner
This pack turned up in five past turnarounds, and the agents read the last three. All 38 steps were carried across, each with its source. Against 604 plant changes, two steps are no longer true. Four lessons were found, one of which does not apply, and the estimate came to 2,056 hours from closed work orders.
02Morning
Six blinds on the list, and a bypass that needs a seventh
Turnaround planner
Step 1.3 is stale. A plant change added a 2-inch warm-up bypass on the shell inlet, and the last pack reused the six-blind list. That opening held the bypass on a locked closed valve under its permit, and a closed valve is not a blind. The agent proposes seven blinds and hands the new one to the isolation coordinator.
03Morning
The crane pad now has a pipe rack across it, and the last crew lost 9 hours
Turnaround planner
Step 2.9 still sets the crawler on the north pad at 58 feet, using the last lift plan. A plant change built a pipe rack across that pad. The last crew moved the crane on the day and lost 9 hours, and nobody fixed the pack. The agent proposes the south pad under a new lift plan from the rigging engineer.
04Morning
The plant change record: a new pipe rack across the north half of the pad
Turnaround planner
The source opens as filed: the change that built the rack to carry new hydrogen and utility lines. Its review asked about access for operations but did not name crane positions or the bundle lift. The as-built survey left 26 feet clear on the pad. Nobody carried that change into the pack, so the last crew found the rack on the day.
05Morning
Studs galled three times, so step 2.2 goes to tensioners
Turnaround planner
Last time, the pack broke the 44 channel cover studs with a torque wrench and heated seized nuts. The lesson matcher shows the studs galled at three turnarounds with the same action written each time, and the lesson cost 11 hours in one of them. The agent proposes hydraulic tensioners, every fourth stud, so no nut turns under load.
0609:09
The planner accepts step 2.2, and six decisions remain
Turnaround planner
The planner accepts the stud change with the reason that the proposal stands as written. The ladder marks step 2.2 accepted and moves on to the next changed step. Each of the seven steps that moved needs its own decision: accept, edit, or reject with a reason. Kept steps carry across with their sources and need no decision, though the planner can still open any of them.
07Next
Nine checks to make on the pad before the pack can be signed
Field walk coordinator
Once the planner has decided every step, someone must go and see. The field walk writer lists it: whether the old pad is blocked, whether the new pad has room and firm ground, and the boom swing path. Stud height above the nut, tensioner clearance and the bypass flange follow, then the lift plan and the new blind on the master list.

The seven steps that moved, and what moved them

Of 38 steps, these are the ones the planner decides.

Step	Status	What moved
1.3	Stale	A plant change added a bypass that needs a seventh blind
2.9	Stale	A pipe rack blocks the crane pad the old pack lifts from
2.2	Changed	Studs off by tensioner after galling three times
6.3	Changed	Anti-seize on the threads, then studs on by tensioner, every fourth stud
4.1	Changed	Eddy current, then IRIS on every open tube
5.1	Changed	A plug allowance of 16 tubes against a limit of 59
6.5	Changed	A grooved metal gasket under the current gasket spec

demoSample data, from the working solution.

Around the pack

Lessons on their steps, the contractor’s view, the pack board and the trail

Four more screens planners, contractors and auditors open.

Past turnaround lessons placed on the job pack steps they affect, with one marked as not applying to this equipment — **Lessons on the step they affect**Past lessons proposed for the step they affect, and one the agent says does not apply, with its reason.

Contractor review of a turnaround work package: packs in the lot, draft hours, and a request for hours on one step — **Contractor review**The contractor planner reads the steps as the crew that does them and asks for hours with a reason; the planner settles each request.

Shutdown work package board: job packs by unit and stage, drafted, with planner, field walk, with checker and issued — **Packs for the turnaround**All job packs by unit and stage, from not drafted to issued, with the changed and stale steps on each.

Work pack automation audit trail: agents drafting and checking, planner decisions with reasons, and pack signatures — **Audit trail**Drafts, step decisions, walks and pack signatures, each with who acted and why. Nobody can edit it.

demoSample data, from the working solution.

Five roles on one pack, and nobody signs their own

Each role reads something different before acting.

Turnaround planner

Sees: Only the steps that moved, each with its source
Signs: Accepts, edits or rejects each changed step

Field walk coordinator

Sees: The walk card for critical packs
Signs: Records what was found on the pad

Contractor planner

Sees: The steps as the crew will do them
Signs: Comments and asks for hours

Lead turnaround engineer

Sees: Each changed step and the walk’s holds
Signs: Signs and issues the pack

Internal auditor

Sees: Who decided each step, and what they read
Signs: Reads and exports evidence

The agents

Seven agents draft the pack, and none decides a step

Where each one stops, and who picks up.

Pack finder

Finds past packs under current and old tags.

Never guesses at an unreadable page

Step drafter

Carries steps across with crew, hours and one source.

Never writes a step without a source

Stale checker

Tests steps against plant changes, drawings, standards and tags.

Never decides
Never writes a lift plan or a blind boundary

Lesson matcher

Places lessons on steps, and says when one does not apply.

Never adds a lesson without a citation

Pack assembler

Builds isolation, materials, permits and QA/QC.

Never changes the master blind list or reserves material

Hours estimator

Sets hours from closed work orders.

Never hides a one-time loss in an average

Field walk writer

Writes what to go and see on the pad.

Never marks a check done

What a planning lead asks before trusting a drafted turnaround work package

What is a turnaround work package?

A turnaround work package, or job pack, holds everything a crew needs for one job: steps, crew, hours, isolation, materials, permits and QA/QC. Here the agents draft each turnaround work package from past packs and standards, cite every step, and mark the steps that moved for the planner to decide.

What happens after the planner decides the steps?

A critical pack goes to the field walk coordinator, who walks the checks on the pad with the contractor and records what was found. Holds such as a lift plan or a new blind must close, and a second person confirms each one. Only then does the lead turnaround engineer open every changed step and sign the pack, which moves it to issued on the pack board.

What does the planner see first when a draft opens?

The steps that moved. Changed and stale steps are marked on the ladder and on a drawing of the equipment, so clicking a part shows its steps. Each one shows the old wording beside the proposal, the agent’s reason with its sources, and how sure it is.

Does it use our shutdown work package template?

It keeps the structure of your live pack: its lines in order, with detail steps numbered under them, so a planner or crew reads the same structure each turnaround. The export template shown here is a sample; your own replaces it.

How is a stale step found?

The stale checker tests each carried step against plant changes, drawings, standards and tags. A step that a plant change has made untrue is flagged with the record that changed it, and the planner decides.

Is this work pack automation?

The drafting is automated; the decisions are not. Every changed or stale step needs the planner, critical packs are walked, and the lead engineer signs.

Can the contractor see and question the steps?

The contractor planner sees the packs in his own lot, reads the steps and asks for hours with a reason. The planner settles each request.

Where do the hours on a turnaround job plan come from?

From closed work orders on the same job, step by step, with any one-time loss shown on its own so an average does not hide it.

Shutdown, Turnaround & Outage

Bring last turnaround’s pack
for one critical job.

We’ll draft this year’s from it and show you which steps moved, and why.

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Turnaround Work Package Planning

A turnaround work package copied forward, old rigging and all

The Problem Today

The Solution

What You Get

A turnaround work package for one exchanger, the steps that moved

38 steps from three past packs: 31 kept, 5 changed, 2 stale

Six blinds on the list, and a bypass that needs a seventh

The crane pad now has a pipe rack across it, and the last crew lost 9 hours

The plant change record: a new pipe rack across the north half of the pad

Studs galled three times, so step 2.2 goes to tensioners

The planner accepts step 2.2, and six decisions remain

Nine checks to make on the pad before the pack can be signed