The Secret of On Schedule Turnarounds
One of the most important planned events for any onshore or offshore facility is when production and operation is halted completely. This process, known as a turnaround, shutdown, or outage, is a major exercise in scheduling and organization, often planned up to a year in advance. It is during this period that operators conduct regular and necessary maintenance, modifications and servicing that is not possible while the facility is online and operational.
Continued Performance and Safety
Steve Westcott is a Senior Construction Manager for GIS but has been on secondment to BP for more than a decade. As a turnaround specialist, Steve is very aware of the prior planning that is vital for a shutdown’s success:
“Here in the Gulf of Mexico, there are facilities of all ages from newly commissioned platforms to facilities that are hitting their third decade of operation. Turnarounds are crucial for the continued performance and safety of the site. Some minor repair projects, providing they fall into the safety parameters stated by the regulatory authorities, are conducted while the facility is operational, but the more dangerous, intricate, and major upgrades need to be prearranged and scheduled during a turnaround.
The hazardous nature of the oil and gases extracted and stored on site is not the only limiting factor, the fundamental difference are personnel numbers. The extra requirement of people needed to execute the work in an offshore facility is the biggest constraint. It’s tied to the number of beds that are available. When additional specialist staff are essential to complete the work, it is impractical to ferry them to and from the facility and shore. For a major event we use what is known as a ‘flotel’ — a floating hotel. When you’re conducting a turnaround, you have two full shifts working round the clock to complete projects in the shortest, scheduled time.”
Time Is Of The Essence
And it is this key point, the scheduled time, that is most important of all for turnarounds. Should a planned shutdown of, for example, thirty days go over time, even by one day, the impact can be significant. This deferred production can have a negative bearing on a company’s planned cash flow.
It is therefore an unprecedented fact that turnarounds must stay on schedule to remain on budget. But what are the factors that determine the success of an on-time turnaround? Steve believes it is accurate, prior planning that delivers a positive result and technology is the key to future success:
Data Driving Predictability
“There are many elements that make a significant impact on turnaround schedules. Once the finalized scopes are agreed, an estimated time for each job can be calculated. Those who calculate the length of time it will take to complete each task, are very good at it, so it’s not the accuracy of estimation that is the issue. Completed work packs for each scope have an itemized and detailed material list and the management and tracking of these materials is crucial. Delays and budget overruns are a given, should a vital piece of equipment be missing, especially when miles out at sea on offshore facilities.
Several of the major energy sector organizations have embraced the digital transformation of their practices and processes. I personally would not want to return to the ‘old ways’ of paper-based tracking and documentation. It was slow, inaccurate and efficiency and effectiveness was not consistent. In our business, we strive for predictability and using digital technology and specialist software helps us do that.
For the full interview with Steve, read our blog.
This article first appeared on the MODS Energy Industry Blog https://blog.mods.solutions/turnarounds-data-drives-predictability
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