Audel Managing Shutdowns, Turnarounds, and Outages / Edition 1

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Don't shut down by accident

A carefully planned shutdown will improve your plant's safety and efficiency, while one that "just happens" can be disastrous. Developed from the author's highly successful seminars, this book takes you step by step through successfully managing production shutdowns. Identify what must be done, schedule equipment and staff, use project-management software, and save both dollars and downtime.
* Prioritize needs and identify what can be accomplished within time and budget constraints
* Determine whether outside help is required
* Schedule the order and priority of projects
* Learn to use CPM (Critical Path Methods) or PERT (Program Evaluation Review Technique)
* Plan for new or additional work that may arise during a shutdown
* Report and document preparation and execution
* Identify and record future needs the shutdown reveals

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Product Details

  • ISBN-13: 9780764557668
  • Publisher: Wiley
  • Publication date: 8/30/2004
  • Series: Audel Technical Trades Series , #14
  • Edition number: 1
  • Pages: 246
  • Product dimensions: 5.26 (w) x 8.26 (h) x 0.54 (d)

Meet the Author

Michael V. Brown has held maintenance management positions and advised Fortune 500 companies. As a founder and President of New Standard Institute, he has designed and implemented maintenance management programs for a diverse group of clients.

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Table of Contents

About the Author xi
Introduction xiii
Chapter 1 Identifying the Work 1
Identifying the Work 2
Reviewing the Maintenance Backlog 3
Identifying Preliminary Work 6
Risk Management 16
Risk Identification 16
Risk Quantification 17
Risk Response Development 18
Risk Response Control 19
Defining and Limiting the Scope 19
Defining the Constraints of the Shutdown 19
Prioritizing the Proposed Work 20
Preliminary Estimates of Proposed Work 21
Determining Contract Work 24
Determining Internal Labor Demands 25
Job Input Cut-Off Date 25
Prioritizing Last Minute Requests 25
Summary 26
Chapter 2 Planning the Work 29
Planning the Shutdown 29
The Shutdown Organization 30
Assigning Responsibility 32
Parts, Material, and Equipment 32
Shipping and Delivery 34
Planning Thought Process 39
Example of a Turnaround Planning Sheet 43
Applying the Planning Thought Process to Large Jobs 46
Example of Planning a Large Job 51
Estimating Tips 54
Determining Elapsed Time and Job Staffing 56
Including Time Required by Operations 57
Work Packages 58
Contracts for Services 59
Types of Contracts 59
Contract Revisions 61
The Bidding Process 61
Bidding Requirements 62
Standard Forms of Construction Contracts 63
General Provisions of a Construction Contract 63
Technical Specifications 69
Reference Standards 71
Summary 71
Chapter 3 Scheduling the Work 73
Critical Path Method (CPM) 73
Logic Network Conventions 74
Preparing a Logic Network 76
Finding the Critical Path 76
Interfering and Free Float 79
Load Leveling 81
Project Duration versus Project Cost 86
Program Evaluation and Review-Technique (PERT) 88
The Monte Carlo Method 92
Project Management Software 96
Choosing the Right Program 97
Sorting and Communicating Information 99
Breakdown Structures 100
Summary 101
Chapter 4 Executing the Project 105
Shutdown Safety 106
OSHA Requirements 106
Developing Daily Schedules 107
Updating Job Status 110
Reporting Project Status 111
Tracking Project Costs 111
Summary 114
Chapter 5 Reporting and Documenting the Shutdown Activity 117
Project Review Meeting 117
Project File 119
Final Report 119
Sample Shutdown Report 120
Safety 121
Discussion of Major Shutdown Jobs 122
Comments and Recommendations 126
Summary 128
Appendix A Boiler Shutdown Example 131
Boiler History 132
The Shutdown 134
Identifying the Work 134
Building the Work List 137
Appendix B Identifying Electrical Work to Be Performed During a Shutdown 145
Electrical Shutdown Checklist 145
Months and Weeks Prior to the Shutdown 145
During the Shutdown 155
Appendix C Machinery Inspection Prior to and During a Shutdown 163
Bearing Data 163
Shaft Alignment Standards 165
Run-Out Measurements 167
Alignment Data Conventions and Checks 168
The Definition of a Line 168
Off-Zero Alignment 170
Gear Drive Inspection Standards 172
Gear Tooth Nomenclature 172
Gear Maintenance 173
Gear Drive Backlash 174
Gear Failure Analysis 175
V-Belt Drives 178
Causes of Belt Slip 179
Incorrect Tension 179
Sheave Wear and Damage 180
Alignment 180
Belt Tensioning 181
Pumps and Mechanical Seals 182
System Curves 183
Pump Characteristic Curves 185
Combined System and Pump Curves 186
Pump Affinity Laws 187
Understanding Cavitation 190
Determining Pump Condition 191
Centrifugal Pump Repair 191
Mechanical Seals 199
Fans 203
Fan Laws 203
Fan Performance Curves 205
Glossary 213
Index 219
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