Reference Manual

www.Turnaround-Network.com

This document is confidential and is protected by agreement(s) between Asset Performance Networks, LLC., and the recipient company. It shall not be shared with any individual or entity, other than that to whom it was intended.

Asset Performance Networks, LLC
3 Bethesda Metro Center, Suite 925 Bethesda, Maryland 20814 U.S.A. www.AP-Networks.com Telephone (240) 683-1001 • Facsimile (240) 683-1009

Turnaround-Network.com

Preface Asset Performance Networks is a knowledge management consulting company whose mission is to drive the refining and chemical industries toward world-class performance in developing, maintaining, and operating manufacturing assets. We are uniquely qualified in developing Best-in-Class processes and tools and deploying these knowledge management products in a user-friendly, web-based environment to achieve world-class competitiveness in projects and turnarounds. The Turnaround-Network.com is an interactive, web-based community of turnaround professionals. The portal has four modules to improve managing turnarounds: • Tools for improving turnaround planning and execution • Process for defining, planning, and executing turnarounds • Reference for accessing reference material grouped by topic areas • Bulletin Board for posting questions and sharing industry Best Practices Our turnaround experience is based on both managing plant-wide turnarounds and developing turnaround management work processes for major refining and petrochemical companies. In addition, we have conducted global benchmarking studies of over one hundred (100) turnarounds and identified industry Best Practices that led to faster, safer, and more cost-effective turnarounds.
For additional information about www.turnaround-network.com or if you have any questions, please contact us at (240) 683-1001.

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Table of Contents Preface.................................................................................................................................ii Introduction..........................................................................................................................1 Relationship with NPRA..................................................................................................2 Software/Hardware Requirements...................................................................................2 Logging In............................................................................................................................5 Self-Registration..............................................................................................................5 Log In as Registered User................................................................................................6 Tools....................................................................................................................................7 Readiness Pyramid...........................................................................................................7 Features........................................................................................................................8 Accessing.....................................................................................................................8 Entering a new turnaround...........................................................................................8 Adding Yourself to an existing evaluation..................................................................9 Completing an Evaluation............................................................................................9 Reports.......................................................................................................................10 Pyramid-Process Guidelines..........................................................................................18 Features......................................................................................................................18 Accessing...................................................................................................................18 Risk Manager.................................................................................................................19 Features......................................................................................................................19 Accessing...................................................................................................................19 Reports.......................................................................................................................21 Process...............................................................................................................................23 Turnaround Work Process.............................................................................................23 Features......................................................................................................................23 Accessing...................................................................................................................23 Job-Aids.........................................................................................................................26 Features......................................................................................................................26 Accessing...................................................................................................................26 Examples....................................................................................................................26 Complexity Calculator...................................................................................................27 Features......................................................................................................................27 Accessing...................................................................................................................27 Reference...........................................................................................................................28 Features..........................................................................................................................28 Accessing.......................................................................................................................28 Bulletin Board....................................................................................................................29 Features..........................................................................................................................29 Accessing.......................................................................................................................30 Common Actions...........................................................................................................30 Help and Support...............................................................................................................33 Appendix A: Glossary........................................................................................................34

© 2008 AP-Networks’ Proprietary All Rights Reserved

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Introduction

Welcome to www.Turnaround-Network.com, an interactive, web-based community of turnaround professionals sharing knowledge and experience via worldclass processes, decision tools, and other expert resources. The portal brings together a company's turnaround teams with other teams in the industry - no matter the location - so that the turnaround community can collaborate and share its invaluable resources. www.Turnaround-Network.com lets you: • Share Best Practices and lessons learned across a community of turnaround professionals • Leverage internal knowledge and outside experience across many facilities • Maintain corporate memory • Facilitate the integration of newly merged companies with common processes, tools, and terms. • Access specific expertise across geographic and organizational boundaries

© 2008 AP-Networks’ Proprietary All Rights Reserved

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select the latest version with the appropriate language of "Acrobat Reader" from the list and click on that link. planning. As part of the agreement.Turnaround-Network. and executing turnarounds • Reference for accessing reference material grouped by topic areas • Bulletin Board for posting questions and sharing industry Best Practices Relationship with NPRA Asset Performance Networks has a formal collaborative agreement with the National Petrochemical and Refiners Association (NPRA). • After you have clicked on the link with the name of your operating system and the new page has loaded. • Download and install the free Flash Player software.com/windows/ie/default. • Follow instructions provided on the Explorer page to download and install a free copy of Internet Explorer.turnaround-network.com/support/downloads/main.html • Under the "Products" column find "Acrobat Reader".Turnaround-Network.e. Software/Hardware Requirements In order to get the most out of www. • Go to http://www.htm. © 2008 AP-Networks’ Proprietary All Rights Reserved 2 Reference Manual 01/08 . • Choose the specific version of Internet Explorer 5. Windows. • You will need a program called Adobe Acrobat Reader to view some of the additional material on this site. Also.com. etc.macromedia. • Your web browser needs a plug-in called Macromedia Flash Player.com/software/flash/download/. your computer will need the following software: • web browser – best results are within Microsoft's Internet Explorer • Macromedia Flash Player • Adobe Acrobat Reader The following free downloads are available: • The web browser that will give you the best result for viewing this site is Microsoft’s Internet Explorer. members of Turnaround Advisory Board are former chairmen of NPRA Maintenance Conference. You can download this browser for free: • Go to http://www.microsoft.0 or newer that is compatible with your computer. • Go to http://www.com enables turnaround professionals to manage knowledge through the following sections: • Tools for improving turnaround planning and execution • Process for defining. NPRA provides APN with information related to turnaround management and maintenance from recent conferences. Macintosh.).adobe.com The www. available on the Internet for free. • Click the link with the name of your operating system (i.

Encryption and firewall technology prevents the review and tampering of information that is entered into www.com service is protected by current industry encryption and firewall technology. therefore.Turnaround-Network. "Step 2".5 or higher • PC users should have Windows 95 or higher You also need to make sure your screen resolution is set properly as follows: • Click on the Start button in the bottom left corner of the screen. Turnaround-Network. • Click the Settings tab. and "Step 3" as provided on the web page that loads in your web browser. For this course. • Click the OK button.com Security Information entered and processed through the www.3 baud modem or better • Java and Javascript capability • Mac users should have OS 7. you only need the basic Acrobat Reader. • Set the color palette to the highest possible setting at your resolution.Turnaround-Network. • "Step 3" provides the actual download of the "Acrobat Reader" installation file. click on "Get Adobe Reader free!" near the bottom of the page. • Close the Control Panel window.com by unauthorized entities.Turnaround-Network. • Follow "Step 1". Your web browser should prompt you to select a location in which to save this file. The hardware requirements you will need to successfully complete a course and to have the best possible web experience are as follows: • A processor with at least 90 MHz clock speed • At least 32 Mb RAM • A SVGA . • Drag the slider in the Screen Area section to either 800 x 600 or 1024 x 768. © 2008 AP-Networks’ Proprietary All Rights Reserved 3 Reference Manual 01/08 .compatible monitor • Minimum 800 X 600 resolution 16 bit color video card • Audio card (does your computer have sound?) • A 33.com • The next web page that loads in your browser will present you with a list of features in the various Adobe Acrobat products. • Follow the prompts given by Microsoft Windows. • Double-click the Display icon. • Highlight the Settings item and click the Control Panel item. Choose a place on your computer where you will be able to easily find the file once the download is complete.

Turnaround-Network.com © 2008 AP-Networks’ Proprietary All Rights Reserved 4 Reference Manual 01/08 .

com. Anyone at the site with internet access and the Group Code can access turnaround-network. the Group Code may change.Turnaround-Network. Self-Registration • Go to www. If you have questions about which group to join. for security reasons. Password. please contact your company representative. Periodically. and Group Code and select “Log In” © 2008 AP-Networks’ Proprietary All Rights Reserved 5 Reference Manual 01/08 .com.Turnaround-Network. the company receives a site license and a Group Code. Note that a company may have multiple groups. but a user can only register with one group.Turnaround-Network. The members of the group which the company provides access to the network will receive the updated Group Code information.com • Select “Register now” • Enter Group Code provided by company and select “Submit” • Complete User Profile and select “Submit” • Enter Name.com Logging In When a company signs-up to www.

com • Enter Name.Turnaround-Network. and Group Code and select “Log In” © 2008 AP-Networks’ Proprietary All Rights Reserved 6 Reference Manual 01/08 .Turnaround-Network.com Log In as Registered User • Go to www. Password.

the Turnaround Pyramid provides links to specific job aids to improve the readiness of specific components. In addition to measuring the overall status and alignment. The benefits of the Readiness Pyramid include: • Effectively evaluate your readiness for the turnaround at any point during the planning phases • Identify gaps between your turnaround’s readiness and our world-class performance measures • Successfully gauge your team’s alignment around critical turnaround issues and attributes • Systematically predict successes and failures with a consistent turnaround evaluation method • Promote team integration and keep communication lines clear with upper management © 2008 AP-Networks’ Proprietary All Rights Reserved 7 Reference Manual 01/08 .com Tools Readiness Pyramid The Readiness Pyramid is a self-assessment tool that enables turnaround teams to measure the readiness of their turnaround relative to Industry Best Practices.Turnaround-Network.

and planning status.com • Select Tools from top menubar • Select Pyramid from left menubar Entering a new turnaround A record can be created within the Turnaround Pyramid for each turnaround being planned by the group.com Features Some key features of the Turnaround Pyramid include: • Evaluate status of a turnaround at any point during the scope development and planning phases. planned start date. The alignment is: o An objective measure of alignment by calculating the deviation between the various answers of the turnaround team members.team members can log into the network and answer the Readiness Pyramid questions from their own desk – there are multiple layers of passwords. • Access the Pyramid • Select “Add New Turnaround” • Enter Turnaround Information. When the record is created. general information about the turnaround (name. including multiple team or consensus. and select “Submit” • Enter Evaluation Information. turnaround leader) is documented. o An enabler of dialogue between team members. The Turnaround evaluation leader creates a record with the background info the first time and the members of the turnaround team enable themselves to complete the evaluation. and select “Submit” • Select “Start Your Evaluation Now” • Add yourself to the evaluation © 2008 AP-Networks’ Proprietary All Rights Reserved 8 Reference Manual 01/08 . and with management • Tried and true method.no outside facilitators or consultants required • Easy to use and secure . location.Turnaround-Network.Turnaround-Network. across functions. The turnaround readiness pyramid has been applied on many turnarounds and is praised by all who have used it • Self-assessment . Accessing • Log into www. The readiness evaluation is: o Comprehensive with 21 major components o Scaleable to the complexity of the turnaround and the timing prior to the turnaround o Identifies gaps with Best Industry Practices o Takes less than 50 minutes to complete without pre-preparation – a great time/value investment • Gauge your team’s alignment around critical turnaround issues. including a password.

selecting this option allows team alignment to be measured by the Pyramid. Note that there are two (2) types of evaluations: Multiple Team Member Evaluation and Consensus Evaluation. Therefore. and move to the next level before making final selection. Ideally. • Click the circle next to the selected level.Turnaround-Network. Importantly. confirm that the current characteristics meet or exceed this description. this option should be used for evaluations done as a team exercise in a facilitated setting. • Select "Finish" if this is the last subcomponent. The two types are discussed as follows: • Multiple Team Member Evaluations allow team members the ability to evaluate the project individually. in circumstances where an individual is performing an evaluation separately from the rest of the team. select "Reports" © 2008 AP-Networks’ Proprietary All Rights Reserved 9 Reference Manual 01/08 .com • Answer the questions Multiple evaluations can and should be created for each turnaround record. The overall project status is calculated as the average from the inputting individual team members. • A Consensus Evaluation allows only one user to provide input. select a planning component • Select the level among the five (5) choices that best describes the current characteristics. it is recommended to start with the first level. Note that the questions are intended to be cumulative. or. Selecting this option precludes the reporting of a team alignment measure. Each team member is given equal weight in determining the overall status. Make sure the circle turns solid and the text box is highlighted after clicking on the level. a turnaround team should create a new evaluation when entering a new planning phase or if there are significant changes in the turnaround characteristics. Adding Yourself to an existing evaluation • Access the Pyramid as described above • Select “Select Existing Turnaround” • Search for the turnaround and click on the name • Enter password provided by turnaround evaluation leader • Click on evaluation name • Select “Start Your Evaluation Now” • Add yourself to the evaluation • Answer the questions Completing an Evaluation • After adding self to evaluation. or "Next" if there is additional subcomponents. • Answer all 21 components • After answering all 21 components. Since the questions within the Turnaround Pyramid account for time and complexity.

Turnaround-Network. do the following: • Access the Pyramid as described above • Select “Select Existing Turnaround” • Search for the turnaround and click on the name • Enter password provided by turnaround evaluation leader • Select "Reports" from the upper right menu • Select the appropriate report © 2008 AP-Networks’ Proprietary All Rights Reserved 10 Reference Manual 01/08 .com Reports To access the reports.

some gaps from Best in Class" • A green light indicates a turnaround that is "Best in Class" The alignment measures the degree of agreement by individual team members on the turnaround status by component. These differences should be discussed and understood before proceeding through the decision date. then the overall status is the average score from the users.Some differences across team in rating project status.com Team Report – Overall Turnaround Readiness The planning status is calculated from the responses provided in the evaluation section for the 21 components of the pyramid. The response of each team member has equal weight in determining the overall status. The Overall Readiness reports are illustrated by the stoplight colors: • A red light indicates a turnaround with "Major gaps from Best in Class" • A yellow light indicates a turnaround that is "Borderline. © 2008 AP-Networks’ Proprietary All Rights Reserved 11 Reference Manual 01/08 . These differences should be discussed and resolved prior to proceeding through decision gate.Substantial differences across team in rating project status. There are three possible ratings: • A red light indicates a turnaround with "Weak Alignment" . This feature provides the turnaround team with an understanding on how well aligned they are as a team on the level of turnaround readiness. If multiple team members perform the evaluation.Turnaround-Network. • A yellow light indicates a turnaround with "Moderate Alignment" .

Turnaround-Network. The Pyramid's alignment feature is only reported for multiple team member evaluations and there must be a minimum of three team members participating in the evaluation for alignment to be displayed. © 2008 AP-Networks’ Proprietary All Rights Reserved 12 Reference Manual 01/08 .com • A green light indicates a turnaround with "Strong Alignment" .Minimal difference across team in rating project status.

© 2008 AP-Networks’ Proprietary All Rights Reserved 13 Reference Manual 01/08 . The user can "drill down" and identify the status and alignment on each major component by double-clicking on the component text.com Team Report – Turnaround Readiness Pyramid The planning status of each components is presented in the Team Report – Turnaround Readiness Pyramid.Turnaround-Network.

© 2008 AP-Networks’ Proprietary All Rights Reserved 14 Reference Manual 01/08 . The user can "drill down" and identify the status and alignment on each major component by double-clicking on the component text. the alignment of each component is presented in the Team Report – Turnaround Readiness Pyramid.com Also.Turnaround-Network.

com Team Report – Turnaround High/Low The High/Low Report shows the five highest rated and five lowest rated components within the current turnaround evaluation. © 2008 AP-Networks’ Proprietary All Rights Reserved 15 Reference Manual 01/08 . primarily to highlight the weakest areas for reevaluation. It is used to show the strongest and weakest attributes of the current turnaround.Turnaround-Network.

Turnaround-Network. place the curser over the planning component in the list on the left. The optimal level is to be well defined AND well aligned – which would be in the upper right quadrant of the graph. © 2008 AP-Networks’ Proprietary All Rights Reserved 16 Reference Manual 01/08 . and the alignment of each component on the other axis.com Team Report – Boston Square The Boston Square Report graphs the current status of each component on one axis. To find a specific component.

Individual Reports include: • Readiness Pyramid for each individual • High/Low Reports for each individual Compare Evaluations includes: • Compare Overall Readiness • Compare Turnaround Status • Compare Turnaround Alignment • Compare Turnaround High/Low © 2008 AP-Networks’ Proprietary All Rights Reserved 17 Reference Manual 01/08 .Turnaround-Network.com Planning Component The user can "drill down" and identify the status on each major component by doubleclicking on the component text.

Turnaround-Network.Work Process Linking Guidelines provides the user with a link between the planning components of the Turnaround Readiness Pyramid and the planning and execution phases of the Turnaround Work Process.com Pyramid-Process Guidelines Features The Turnaround Pyramid . and the document will summarize the key activities for that component by planning and execution phase. Accessing • Log into www.Turnaround-Network.com • Select Tools from top menubar • Select Pyramid-Process Guidelines from left menubar © 2008 AP-Networks’ Proprietary All Rights Reserved 18 Reference Manual 01/08 . Select a Pyramid component.

In addition to providing risks with specific outcome performances (e.no outside facilitators or consultants required • Analyze and close gaps .g. the risk manager also highlights specific planning components to focus on in order to minimize the impact of these potential risks.results indicate specific planning components to focus on and provides links to job-aids Accessing • Log into www. and operability).com • Select Tools from top menubar • Select Risk Manager from left menubar • Select "Begin Risk Analysis" © 2008 AP-Networks’ Proprietary All Rights Reserved 19 Reference Manual 01/08 . Features Some key features of the Risk Manager include: • Easy to use .answer a series of questions about the turnaround in about 15 minutes • Self-assessment . safety.Turnaround-Network.com Risk Manager The Risk Manager is a self-assessment tool that enables turnaround teams to assess the relative risk of their turnaround based on the characteristics. cost. startup. schedule.Turnaround-Network.

com • • • Answer the questions and select "Calculate Risk" View the Risk Profile View planning component results by selecting "Pyramid" © 2008 AP-Networks’ Proprietary All Rights Reserved 20 Reference Manual 01/08 .Turnaround-Network.

Turnaround-Network.com Reports Risk Profile © 2008 AP-Networks’ Proprietary All Rights Reserved 21 Reference Manual 01/08 .

com Planning Components © 2008 AP-Networks’ Proprietary All Rights Reserved 22 Reference Manual 01/08 .Turnaround-Network.

execution. through definition.Turnaround-Network.com • Select Process from top menubar • Select Turnaround Work Process from left menubar • Select a Phase from left menubar • Select Process Step or Phase Characteristic for more info • Select highlighted text for Glossary and Job-Aids © 2008 AP-Networks’ Proprietary All Rights Reserved 23 Reference Manual 01/08 . Within each phase there is a set of process steps (activities and deliverables) that have to be completed. event-free.com Process Turnaround Work Process Empower your team with our comprehensive world-class turnaround management process and associated job aids. and predictable turnarounds. starting with setting objectives. Job-aids and definitions are integrated into the phases and process steps. and post turnaround activities. planning. Our process is an electronic roadmap for achieving safe. Features The turnaround work process has eight phases and five phase reviews. Accessing • Log into www.Turnaround-Network. where available.

com Process Phase © 2008 AP-Networks’ Proprietary All Rights Reserved 24 Reference Manual 01/08 .Turnaround-Network.

com Process Step © 2008 AP-Networks’ Proprietary All Rights Reserved 25 Reference Manual 01/08 .Turnaround-Network.

Turnaround-Network.Turnaround-Network. job-aids for key activities in the specific phases and process steps are available for users. Features The types of job-aids include: • Checklists • Guidelines • Procedures • Report Templates Accessing • Log into www.com • Select Process from top menubar • Select Job-Aids from left menubar Examples Bid Package Management List Capital Project Integration Checklist Capturing Lessons Learned Contractor Performance Evaluation Final Turnaround Execution Plan Guidelines Inspection Checklist Labor Hours Definition Lessons Learned Action Item List Milestone Schedule Checklist Post-Turnaround Questionnaire Pre-Shutdown Execution Plan Guidelines Preliminary Execution Plan Guidelines PreShutdown Planning Checklist Procedure Management List Procurement Management List Resource Management List Roles and Responsibilities Safety Plan Team Involvement Turnaround Accounting Rules Turnaround Execution Reporting Matrix Turnaround Meeting Guidelines Turnaround Reference Book Guidelines Worklist Challenge Session Work Breakdown Structure © 2008 AP-Networks’ Proprietary All Rights Reserved 26 Reference Manual 01/08 .com Job-Aids As part of the Turnaround Work Process. These PDF documents are based on industry Best Practices and are intended to help turnaround managers and team members plan and execute the turnaround more efficiently.

Turnaround-Network.Turnaround-Network. Medium. Turnaround complexity is determined by the following characteristics: • percentage of engineered capital in the planned scope.com categorizes the risk as High. or Low based on some high level characteristics.Turnaround-Network. • planned number of labor hours.com Complexity Calculator Features Recognizing that different turnarounds have different levels of complexity.com • Select Process from top menubar • Select Complexity Calculator from left menubar © 2008 AP-Networks’ Proprietary All Rights Reserved 27 Reference Manual 01/08 . Accessing • Log into www. • and duration since the last planned turnaround.

Accessing • Log into www.Turnaround-Network.com with publications related to turnaround management and maintenance from recent conferences through a collaborative arrangement. National Petrochemical and Refiners Association (NPRA) provides TurnaroundNetwork.com Reference Features The Reference section of Turnaround-Network.com • Select Reference from top menubar • Select a topic from left menubar • Select Abstract.com contains lists of articles and other reference material grouped by topic area.Turnaround-Network. Text Document. or Presentation © 2008 AP-Networks’ Proprietary All Rights Reserved 28 Reference Manual 01/08 .

com allows users to network with professionals by posting topics and replying to messages. • Select “Search Messages” for searching messages by key word or date.com Bulletin Board The Bulletin Board section of Turnaround-Network. creating topics) within conferences. e-mailing. • Messages Menu for listing messages.e. including: • All messages • New messages • Text Window for reading and entering text and for viewing and changing options The messages on the Bulletin Board are organized as follows: © 2008 AP-Networks’ Proprietary All Rights Reserved 29 Reference Manual 01/08 . and messages. including: • Select "Home" for general information • Select “Post Message” for posting new messages (i.Turnaround-Network. Features The home page of the Bulletin Board is divided into three (3) sections: • Left Navigation Tab Menu for quick access to common actions. • Select “More Options” for profiles.

As a registered user of Turnaround-Network.e.com.com • Select Bulletin Board from top menubar • Select "Global" or Company-specific board Common Actions How do I view a message? • Select a conference • Select a message within the conference • The original message and all replies will appear in the text window How do I post a message (i. Users can create topics within the conferences by posting a new message.Turnaround-Network. • Messages are posted and replied to within the topic area by the users. • Topics are the next level message grouping within the Bulletin Board.Turnaround-Network. create a topic)? • Click on a conference in the Messages Menu so that a “-“ appears • Select “Post” from the Left Navigation Tab Menu • Enter topic • Click on appropriate options • Enter text • Select “Post” • Correct spelling errors • Select “Post” OR • Select “Post” from the top menu of the message within a conference and proceed as above OR • Select “Post new Topic” at the end of the last reply message of a topic and proceed as above How do I reply to a message? • View a message • Select “Reply” from the top menu of the message • Proceed with post a message as described above OR © 2008 AP-Networks’ Proprietary All Rights Reserved 30 Reference Manual 01/08 . you gain access to two user groups: • Global – which can be accessed by all registered users within the network • “Group Name” – which can only be accessed by users registered with this group Accessing • Log into www.com • Conferences are the highest-level message grouping within the Bulletin Board. The Group Administrator creates the conferences within the Bulletin Board.

if necessary • Select highlighted text with number of new messages in text window OR • Select New Messages from the Message Menu How do I view today’s messages? • Select “Search” from the Left Navigation Tab Menu • Select “Today’s Messages” within the text window OR • Select “More Options” from the Left Navigation Menu Bar • Select “Today’s Messages” within the text window How do I attach a file? • Post a message or reply to a message • Click the box for Attach file • Select “Post” at the bottom of the text window • Correct spelling errors • Select “Post” • Click “Browse” and select file • Select “Upload Now” How do I delete my posted message? • View a message • Select “Delete” from the top menu of the message Note: You can only delete messages you posted.com • View a message • Select “Reply to: ” at the end of the last reply message of a topic and proceed as above How do I search for a message? • Select “Search” from the Left Navigation Tab Menu • Complete information for “Key Word Search” or “Date Range Search”. as appropriate © 2008 AP-Networks’ Proprietary All Rights Reserved 31 Reference Manual 01/08 . not anyone else’s • Edit the message.Turnaround-Network. not anyone else’s • Select “Yes” How do I edit my posted message? • View a message • Select “Edit” from the top menu of the message Note: You can only edit messages you posted. as appropriate • Click “Search” within the text window • Select Topic text to view the message How do I view new messages? • Select “Home” from Left Navigation Menu Bar.

Turnaround-Network.com • • • Select “Post” Correct spelling errors Select “Post” How do I go to a different User Group? • Select “Bulletin Board” from standard tabs across the top • Select the appropriate User Group How do I mark messages as read? • Select “More Options” from the Left Navigation Menu Bar • Select “Mark All Read” within the text window © 2008 AP-Networks’ Proprietary All Rights Reserved 32 Reference Manual 01/08 .

com.com. which will be responded to by a technical specialist within 24 hours.Turnaround-Network.com and Help for Readiness Pyramid.com home page. Support is available through both email and telephone.com Help and Support Frequently Asked Questions are available to answer common questions new users may have about the Turnaround-Network. These are accessible from the top right tabs of the respective sections. These are accessible from the left tab on the login page and Turnaround-Network. Telephone technical support is also available Monday – Friday at (240) 683-1001 from 9:00 AM to 5:00 PM EST.com home page. © 2008 AP-Networks’ Proprietary All Rights Reserved 33 Reference Manual 01/08 . Help is available in two sections: Help for Turnaround-Network. Glossary is available to define commonly used terms within Turnaround-Network. An email can be sent to Technical Support. These are accessible by selecting the highlighted text within the appropriate section or from the left tab of the Turnaround-Network.

Integration Capital Projects Job Aids: Capital Projects Integration Checklist Turnaround Work Process . Capital Project Portfolio © 2008 AP-Networks’ Proprietary All Rights Reserved 34 Reference Manual 01/08 . indirect labor. Also. Developed by cross-disciplined teams and based on economic analysis. there should be detailed calculations. records. in review.Team Capital Projects . Capital Projects Capital Projects are typically performed during the Turnaround of a Process Plant. the direct labor. the ownership of the engineering packages should be clearly defined. as appropriate. Capital Projects-Integration Capital Projects should be integrated with the Maintenance activities with the same Planning and Scheduling methods. the priority of the capital projects should also be clearly communicated. In addition. Capital Projects-Team The Capital Projects representatives should be integrated into the Turnaround Team. Also.Turnaround-Network. It is also beneficial that the same management team that manages the Turnaround effort direct the capital effort during the period immediately before and during the Turnaround window. there should be seamless coordination with Maintenance. or released. as appropriate. The estimate should include Expense.15 percent. and Engineered Capital as major categories. and quotations to support the estimate. Sub-Component Analysis: Capital Projects . The plans should include both a Long Term Strategy and a Definitive Two Year Plan Authorization Cost Estimate A deliverable of the Detailed Planning Phase. Maintenance Capital. these plans provide the basis for improving the performance of the asset.Pyramid Component Linkage Capital Projects-Engineering Packages The Engineering Packages should be tracked during the Turnaround planning phases as being in-process. the authorization cost estimate is prepared with a level of accuracy of +/.Engineering Packages Capital Projects . In addition. and materials for each major category should also be included in the estimate. In addition.com Appendix A: Glossary Asset Improvement Plans Asset Improvement Plans are deliverables from the Long Range Strategy Phase of the work process. or better.

Pyramid Component Linkage Completed Turnaround Work A deliverable of the Turnaround Execution Phase. and materials for each major category should also be included in the estimate. and this component relates to the owner's contracting strategy and process for selecting contractors. Communications The appropriate communication of turnaround goals and progress to achieving these goals is essential to the success of Turnaround.Turnaround-Network. The estimate should include Expense. Daily and weekly meetings to establish priorities and resolve issues must be well planned and disciplined to be effective.com The capital project portfolio is a prioritized list of capital projects and plant modifications that clearly defines the specific value. Contingency Planning During this phase all potential risks that threaten the turnaround execution goals are assessed on a basis of Likelihood and Consequence of Occurrence. This report captures all the planning and execution activities and can be used to capture lessons learned for future turnarounds of the same or similar processes. as well any additional activities added to the scope of work. The accuracy of the estimate should be about +/. Sub-Component Analysis: Contingency Planning .Sub-Components Contingency Planning Job Aids: Turnaround Work Process . payback. the direct labor. this work includes all capital and expense activities planned and executed. and prioritization of each project. Communication between shifts and units that must be worked together are also important.Sub-Components Communications Job Aids: Turnaround Meeting Guidelines Turnaround Work Process . Also. indirect labor.Pyramid Component Linkage Contractors Contractors play a critical role in the planning and execution of a Turnaround. and Engineered Capital as major categories. Maintenance Capital. Sub-Component Analysis: © 2008 AP-Networks’ Proprietary All Rights Reserved 35 Reference Manual 01/08 . Comprehensive Report A Comprehensive Report of the turnaround is a deliverable of the Post-Turnaround Phase. Conceptual Cost Estimate A Conceptual Cost Estimate is a deliverable of the Concept Phase. Sub-Component Analysis: Communications . For all high risk items contingency plans to appropriately deal with the risk should be established.30 percent.

Sub-Component Analysis: Cost Estimating . If the completion of any activity is delayed. each of these cost is tracked as part of the overall cost control effort. specialty or general are most effective. A good estimating method permits cost tracking and control and financial projections once the work initiates.Pyramid Component Linkage Contractors-Contractor Selection The process for selecting contractors relates to the effectiveness of the selection criteria and the timeliness of the strategy and selection. the completion of the turnaround will also be delayed. The schedule is based on the longest sequence of essential worklist activities that determines the minimum time a turnaround can be completed. with a work-week manager. Typically the type of work scope must be compatible with type of contractor and the appropriate contract form that is established. This sequence of critical work activities is called the "critical path. Consideration should also be given to the utilization of incentive contracts.Sub-Components Cost Estimating Job Aids: Turnaround Accounting Rules Turnaround Work Process .Pyramid Component Linkage Critical Path Schedule A Critical Path Schedule is a deliverable of the Definition Phase and establishes a schedule of key planned work." Daily Routine Maintenance Maintenance performed on operating equipment on a day-to-day basis. by category. schedule compliance. not completed work. Contractors-Contracting Strategy The planning element includes the strategy to perform the work includes how the contracts should be structured and what type of contractors.Contracting Strategy Contractors Job Aids: Contractor Bid Package Management List Contractor Performance Evaluation Turnaround Work Process . an organization would have both a rolling 13 week schedule process and a rolling 4 week schedule reviews and freeze.Contractor Selection Contractors . indirect and overhead costs. Typically the cost is categorized into direct. not scheduled. and reasons for scheduled. Typically. Detailed Planning © 2008 AP-Networks’ Proprietary All Rights Reserved 36 Reference Manual 01/08 .Turnaround-Network.com Contractors . percent completed. Cost Estimating The cost estimating process is performed sequentially with more precise definitive estimates available when the detail planning is complete. Typically metrics include percent backlog by system.

It should also include the coordination of mobilization. training. and tagout Inspection activities I&E activities Predictive. procedures tools. such issues as the handling of mischarges and monitoring fieldwork progress are also identified. scaffolding etc. In Detailed planning materials required to perform the work are usually requisitioned and allocated.Pyramid Component Linkage Detailed Pre-Shutdown Schedule A deliverable of the Pre-Shutdown Planning Phase. schedule.Turnaround-Network. preventative & corrective maintenance activities Capital project work Field support e. Sub-Component Analysis: Execution Control . QA/QC points Testing Startup Production ramp up Execution Control This phase of the planning process is related to the methods for controlling cost.g.Sub-Components © 2008 AP-Networks’ Proprietary All Rights Reserved 37 Reference Manual 01/08 .Sub-Components Detailed Planning Job Aids: Final Turnaround Execution Plan Guidelines Turnaround Work Process . Job Walk downs with contractors are also performed during this phase of the planning process. and training plans for contract and owner personnel. In addition. the detailed schedule should integrate all the capital and expense activities for the turnaround execution phase. and fieldwork activities for the pre-shutdown phase. Typically plant shutdown and startup sequences and procedures are developed. Detailed Turnaround Schedule A deliverable of the Detailed Planning Phase. and percent work completion during the turnaround execution. equipment and materials. the detailed schedule should integrate all the mobilization. Sub-Component Analysis: Detailed Planning . cleanup. including Shutdown. including Tagout/lockout activities Permits Support activities Schedule of heavy machinery The Pre-Shutdown Schedule should be integrated with the daily schedule and the turnaround schedule. drawings. reviewed and validated by operational planning representatives.com During this phase of the Planning Process the work scope is broken down into job packages which provide all the information to perform the work in the field including trade allocation.

Pyramid Component Linkage Key Management Lists Key Management Lists are deliverables of the Definition Phase and are used to help manage key planning aspects at the turnaround manager level. which must be addressed.Pyramid Component Linkage Frozen Worklists Frozen Worklists are deliverables of the Definition Phase. see the Risk Manager Tool within the Tools section. After issuing the Frozen Worklists. and include both the Turnaround Worklist and the Pre-Shutdown Worklist. resource availability. number of field workers. Reliability Engineering.g.Turnaround-Network. During the Turnaround a key reliability process to assure mechanical integrity is an inspection plan to find any issues. new procedures.Sub-Components Inspection Job Aids: Inspections Checklist Turnaround Work Process .) and after going through a challenge session to optimize the scope. Operations. Examples of key management lists include: Procurement Management List Bid Packages Management List Resource Management List Procedure Management List Lessons Learned Action Item List Lessons Learned © 2008 AP-Networks’ Proprietary All Rights Reserved 38 Reference Manual 01/08 . The worklist should be frozen only after getting the input of key functions (e. For more information. High Potential Risk Areas Certain inherent characteristics of turnarounds can lead to high potential risks. the turnaround team should initiate a documented scope control process. Inspections. Some of the areas include: percent of engineered capital within the scope. Engineered Capital Projects. The lists should be created during the Definition Phase in order to understand the magnitude of each planning component. The utilization of Risked Based Inspection techniques to establish the Inspection scope is being increasingly used by many organizations to effectively focus the Inspection effort. etc. Sub-Component Analysis: Inspections . Maintenance. Inspections This key functional group typically provides a large portion of the Turnaround scope. etc. and used to track progress during the other planning phases. It is necessary that the Inspections findings from previous Turnarounds and any in-process inspections be accommodated in the work scope. commercially unproven technology.com Execution Control Job Aids: Turnaround Execution Reporting Matrix Turnaround Work Process .

rationale. schedule. Typically this should be projected for two to three Turnaround cycles. list of major scope items. Key part of this process is to understand previously encountered issues with improvement action items assigned to individuals with deadline dates for completion. At this phase the plan to control and distribute and stage the material is established. Materials Management During this Phase Materials are ordered and / or allocated and usually by equipment or project number with the computerized maintenance system. Effective Long Range Planning permits sound management of Capital Projects together with Operational and Reliability Issues and permits an organization to better allocate its Human and financial resources. Sub-Component Analysis: Lessons Learned . critical requirements. and Economic Decision Models. Sub-Component Analysis: Long Range Plan .Pyramid Component Linkage Long Range Plan Long range planning is the process for establishing Turnarounds based on Reliability Issues. work list criteria.Sub-Components Materials Management Job Aids: Procurement Management List Turnaround Work Process .Sub-Components Lessons Learned Job Aids: Capturing Lessons Learned Lessons Learned Action Item List Post-Turnaround Questionnaire Turnaround Work Process .Pyramid Component Linkage Loss of Production The contribution to financial profits (contribution to margins) of the value of the product(s) that would have been normally manufactured during the turnaround period if the turnaround was not to commence. Capital Planning.Sub-Components Long Range Plan Job Aids: Turnaround Work Process . safety awareness. Contracts with all execution contractors and shops for component overhaul area also completed. and timing. The Turnaround Team can effectively communicate to the organization the goals. Sub-Component Analysis: Materials Management . On-spec Production © 2008 AP-Networks’ Proprietary All Rights Reserved 39 Reference Manual 01/08 . cost.com A systematic study of critiques of previous Turnarounds and large capital projects is an important element in the preparation for a successful Turnaround.Turnaround-Network.Pyramid Component Linkage Objectives Letter The Turnaround Objectives Letter is a deliverable of the Concept Phase.

com As a deliverable of the startup phase. In addition. as appropriate. grouping.Pyramid Component Linkage Work Breakdown Structure Post-Turnaround Worklist The list of items identified after the completion of the Turnaround Execution Phase that still need to be completed after the turnaround is completed. which are identified. bills of materials. Sub-Component Analysis: Pre-Shutdown Planning .Sub-Components Pre-Shutdown Planning Job Aids: Pre-Shutdown Execution Plan Guidelines Pre-Shutdown Planning Checklist Turnaround Work Process . Appropriate manpower planning should be completed and used as an opportunity to mobilize and train the turnaround work force. procedures.Pyramid Component Linkage Pre-Shutdown Work A deliverable of the Pre-shutdown phase. Pre-Shutdown Work Plans Work plans are deliverables of the Pre-shutdown Planning Phase at the appropriate level of detail and reflect a segment. training and fieldwork activities (both capital and expense). or portion of work. The Planning Process considers logistical issues to optimize the work and to assure that all advanced preparations are complete. Planning Practices Planning is the process of analyzing the work scope to determine how it most effectively could be performed in the field. this work includes all the mobilization. Pre-Shutdown Planning All work scope opportunities which can be performed before the Turnaround should be planned and scheduled. Sub-Component Analysis: Planning Practices . drawings. Procedure Status Comprehensive review and revision of all procedures anticipated to be used during the Turnaround should be performed.Sub-Components Planning Practices Job Aids: Preliminary Execution Plan Guidelines Turnaround Work Process .Turnaround-Network. This phase includes the establishment of training packages for any new or revised procedures. plant shutdown and startup sequencing is often performed in this preparatory phase of the Turnaround Process. Sub-Component Analysis: © 2008 AP-Networks’ Proprietary All Rights Reserved 40 Reference Manual 01/08 . ownership of process equipment is transferred back from the turnaround team to operations and the plant is at steady-state operations when it produces saleable on-spec product. The work plans contains all the necessary instructions.

g. From that list. RBI is both a qualitative and quantitative process for systematically combining both the likelihood of failure and the consequence of failure.Pyramid Component Linkage Readiness Assessment At multiple points prior to the Turnaround start date.Pyramid Component Linkage Resource Planning Resource Planning involves the determination of skilled craft requirements and the staffing needs of the Turnaround management organization. definition detailed planning. and execution). Risk Based Inspection Risk-based inspection (RBI) is an integrated methodology that factors risk into inspection and maintenance decision making.Turnaround-Network.Sub-Components Procedure Status Job Aids: Procedure Management List Turnaround Work Process . Sub-Component Analysis: Readiness Assessment . It is recommended that this assessment be performed by the Turnaround Team and by an outsider with turnaround experience to act as independent review of the readiness. to establish a prioritized list of total risk. a Readiness assessment should be performed. by function (e.com Procedure Status . the RBI user has the opportunity to design an inspection program that manages (reduces or maintains) the risk of equipment failures. Sub-Component Analysis: Resource Planning . Logistical issues and shift schedules are also addressed during this phase of the process.Pyramid Component Linkage Resource Requirements Resource requirements are a deliverable of the Concept Phase.g. pre-shutdown.Sub-Components Readiness Assessment Job Aids: Turnaround Work Process . owner or contractor). which should be updated for each phase during the Turnaround Planning and Execution.g. engineering support and field construction). The requirements should be broken down by phase (e. This process will uncover prioritized areas of concern that should be addressed in a short time frame. This involves the development of site wide safety guidelines and training requirements and training packages for the workers to be brought on site. During this phase job level © 2008 AP-Networks’ Proprietary All Rights Reserved 41 Reference Manual 01/08 . Safety Planning Planning is an essential tool to obtain excellent safety performance in the Turnaround. and by type (e.Sub-Components Resource Planning Job Aids: Resource Management List Turnaround Work Process .

During this phase the critical path and the manpower resources required to perform the work are typically determined.Pyramid Component Linkage Scheduling Practices The Process to sequence the work in the most effective manner is part of the scheduling phase of the work process.Turnaround-Network.. including maintenance.Out and Personal Protective Equipment are determined. & Evaluation © 2008 AP-Networks’ Proprietary All Rights Reserved 42 Reference Manual 01/08 . Prioritization. For a large Turnaround the scheduling is typically performed with a computerized Scheduling Program that allows " What If " type analysis. inspections. Sub-Component Analysis: Safety Planning . and startup phases. Scope of Work The scope of work for the turnaround refers to all the activities which need to be planned and executed during the shutdown. must be able to be progressed in the field to establish proper control of the workflow. Sub-Component Analysis: Scope of Work . Projects or jobs added to the worklist after this date should have a more rigorous approval process and are categorized separately (e. The schedule.Scope Analysis. Sub-Component Analysis: Scheduling Practices . add-on work).Scope Growth Control Scope of Work Job Aids: Turnaround Work Process .Pyramid Component Linkage Scope Control Process A documented and rigorous approval process initiated after the Scope Freeze Date that any additional worklist item submitted must go through before being added to the worklist. execution.com safety analysis is performed to establish appropriate safety procedures such as LockOut / Tag. This date typically marks the end of the Definition Phase and results in a Frozen Worklist. Scope Freeze Date Scope freeze date is the date at which the final worklist is established. Prioritization & Evaluation Scope of Work . The scope includes all types of activities.Pyramid Component Linkage Worklist Challenge Process Scope of Work-Analysis.Sub-Components Safety Planning Job Aids: Safety Plan Turnaround Work Process .Scope Development Scope of Work . and capital projects.g.Sub-Components Scheduling Practices Job Aids: Labor Hours Definition Milestone Schedule Checklist Turnaround Work Process . which is developed.

percent add-on work.Pyramid Component Linkage Turnaround Goals Turnaround goals are deliverables from the Long Range Strategy Phase of the work process.Turnaround-Network. cost. as well as some of the practices (e. They are meant to capture the primary goals and outcomes of the turnaround. etc. but should be stakeholders that are knowledgeable with the turnaround process and its key deliverables. and empowering the team to succeed. schedule. and timing in order for the turnaround to be viewed as successful. Sub-Component Analysis: Training . Scope of Work-Scope Growth Control After the scope is frozen a structured rigorous process to add or delete work is required to control and account for any changes to the total work effort. Integration of all work activities in one comprehensive scope document is believed to be essential. providing appropriate resources. Turnaround Steering Committee The Turnaround Steering Committee is a cross-functional team with the ability to enable the turnaround team by removing barriers. actual freeze date versus planned. They will not be involved in the day-to-day details of the planning and execution of the turnaround. cost. This date also marks the beginning of the shutdown phase within the Turnaround Execution. this refers to the commitment by the turnaround team to plan a minimum scope of work and establish a process for analyzing and scrutinizing the scope of work. This involves site specific safely training for all the workers as they are mobilized on site. © 2008 AP-Networks’ Proprietary All Rights Reserved 43 Reference Manual 01/08 . including the general scope.com After developing the scope of work. Scope of Work-Scope Development A systematic disciplined approach to gathering the work scope and preparing the final scope document is a critical activity that must be performed early in the conceptual planning phase of the Turnaround. Operational and Maintenance training for new equipment or processes is also completed during this phase of the preparation process. Turnaround Performance Metrics Key performance metrics related to the turnaround outcomes (safety. Training A Training Plan for all necessary training including how and who will perform the Training is established. and operability).Sub-Components Training Job Aids: Turnaround Reference Booklet Guidelines Turnaround Work Process .) Turnaround Start Date The turnaround start date is the date when the process shutdown begins.g.

Building Process Turnaround Team . the alignment of the Turnaround team members. especially with respect to the level of senior management support. Team Building to build alignment among the team members on key issues is essential to successful Turnaround execution. or portion of work. work that cannot be performed while the unit is running or is economically unattractive to do so.g. as appropriate. as well as the defining of roles and responsibilities.Pyramid Component Linkage Turnaround Team-Building Process The team building process relates to whether formal team building activities are part of the planning process. It is important that the team members clearly understand their Roles and Responsibilities and work in an effective manner.com Turnaround Team The Management of a Turnaround from conceptual stage to completion is a team effort. procedures. Turnaround Work Plans Work plans are deliverables of the Detailed Planning Phase at the appropriate level of detail and reflect a segment. Turnaround Team-Leadership & Composition The leadership and composition of the Turnaround Team relates to the selection and participation of team members.Organization Turnaround Team Job Aids: Roles and Responsibilities Team Involvement Turnaround Work Process . Sub-Component Analysis: Turnaround Team . and the empowerment of the team members.Leadership & Composition Turnaround Team .Turnaround-Network. the responsibility for the outcome of the turnaround. Worklist Criteria The criteria used to prioritize worklist items in order to optimize the scope of work e. grouping. materials. The work plans contains all the necessary instructions. Setting aggressive team goals with consistent performance feedback is an important aspect of the team process. Turnaround Team-Organization The organization influences the Turnaround Team. and the effectiveness of feedback from the leadership team. Safety or Environmental Requirement Inspection Requirement Profitability Item Compelling Operating or Mechanical Need © 2008 AP-Networks’ Proprietary All Rights Reserved 44 Reference Manual 01/08 .

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