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. • After you have clicked on the link with the name of your operating system and the new page has loaded.com/support/downloads/main.e.macromedia.microsoft.0 or newer that is compatible with your computer. As part of the agreement.com enables turnaround professionals to manage knowledge through the following sections: • Tools for improving turnaround planning and execution • Process for defining.com The www. 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.com/windows/ie/default.htm.turnaround-network. Software/Hardware Requirements In order to get the most out of www. © 2008 AP-Networks’ Proprietary All Rights Reserved 2 Reference Manual 01/08 . • Your web browser needs a plug-in called Macromedia Flash Player. 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).adobe. • You will need a program called Adobe Acrobat Reader to view some of the additional material on this site. Macintosh. • Go to http://www. • Click the link with the name of your operating system (i.com. Also.html • Under the "Products" column find "Acrobat Reader".Turnaround-Network. planning. Windows. etc. available on the Internet for free.com/software/flash/download/.Turnaround-Network. • Download and install the free Flash Player software. • Follow instructions provided on the Explorer page to download and install a free copy of Internet Explorer.). You can download this browser for free: • Go to http://www. • Go to http://www. NPRA provides APN with information related to turnaround management and maintenance from recent conferences. • Choose the specific version of Internet Explorer 5.

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

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

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

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

Turnaround-Network. In addition to measuring the overall status and alignment.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. the Turnaround Pyramid provides links to specific job aids to improve the readiness of specific components. 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 .

Turnaround-Network. Accessing • Log into www. 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. When the record is created. The turnaround readiness pyramid has been applied on many turnarounds and is praised by all who have used it • Self-assessment . and planning status. location.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. turnaround leader) is documented. o An enabler of dialogue between team members. general information about the turnaround (name. 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. • Access the Pyramid • Select “Add New Turnaround” • Enter Turnaround Information.team members can log into the network and answer the Readiness Pyramid questions from their own desk – there are multiple layers of passwords. 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. across functions.no outside facilitators or consultants required • Easy to use and secure .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. including multiple team or consensus. and select “Submit” • Enter Evaluation Information.Turnaround-Network. and with management • Tried and true method. 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 . including a password.

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

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 .Turnaround-Network.com Reports To access the reports.

These differences should be discussed and understood before proceeding through the decision date. If multiple team members perform the evaluation.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. These differences should be discussed and resolved prior to proceeding through decision gate. • A yellow light indicates a turnaround with "Moderate Alignment" .Substantial differences across team in rating project status. © 2008 AP-Networks’ Proprietary All Rights Reserved 11 Reference Manual 01/08 .Turnaround-Network. 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.Some differences across team in rating project 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. then the overall status is the average score from the users. The response of each team member has equal weight in determining the overall status. This feature provides the turnaround team with an understanding on how well aligned they are as a team on the level of turnaround readiness. There are three possible ratings: • A red light indicates a turnaround with "Weak Alignment" .

© 2008 AP-Networks’ Proprietary All Rights Reserved 12 Reference Manual 01/08 .com • A green light indicates a turnaround with "Strong Alignment" .Turnaround-Network.Minimal difference across team in rating project status. 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.

Turnaround-Network.com Team Report – Turnaround Readiness Pyramid The planning status of each components is presented in the Team Report – Turnaround Readiness Pyramid. © 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.

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

primarily to highlight the weakest areas for reevaluation. It is used to show the strongest and weakest attributes of the current turnaround.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 .Turnaround-Network.

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

Turnaround-Network. 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 .com Planning Component The user can "drill down" and identify the status on each major component by doubleclicking on the component text.

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 .Turnaround-Network. Select a Pyramid component.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. and the document will summarize the key activities for that component by planning and execution phase.com Pyramid-Process Guidelines Features The Turnaround Pyramid .

no outside facilitators or consultants required • Analyze and close gaps .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 .Turnaround-Network. cost. startup. and operability). In addition to providing risks with specific outcome performances (e.answer a series of questions about the turnaround in about 15 minutes • Self-assessment .Turnaround-Network. the risk manager also highlights specific planning components to focus on in order to minimize the impact of these potential risks. schedule.results indicate specific planning components to focus on and provides links to job-aids Accessing • Log into www. safety.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. Features Some key features of the Risk Manager include: • Easy to use .g.

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

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

event-free.Turnaround-Network. where available. Accessing • Log into www. Our process is an electronic roadmap for achieving safe. through definition. and predictable turnarounds. starting with setting objectives.com Process Turnaround Work Process Empower your team with our comprehensive world-class turnaround management process and associated job aids. Features The turnaround work process has eight phases and five phase reviews.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 . planning. Job-aids and definitions are integrated into the phases and process steps. Within each phase there is a set of process steps (activities and deliverables) that have to be completed.Turnaround-Network. and post turnaround activities. execution.

Turnaround-Network.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 .

com Job-Aids As part of the Turnaround Work Process.Turnaround-Network. Features The types of job-aids include: • Checklists • Guidelines • Procedures • Report Templates Accessing • Log into www. job-aids for key activities in the specific phases and process steps are available for users.Turnaround-Network. 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.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 .

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

com • Select Reference from top menubar • Select a topic from left menubar • Select Abstract.Turnaround-Network.Turnaround-Network. National Petrochemical and Refiners Association (NPRA) provides TurnaroundNetwork.com contains lists of articles and other reference material grouped by topic area. or Presentation © 2008 AP-Networks’ Proprietary All Rights Reserved 28 Reference Manual 01/08 . Text Document.com with publications related to turnaround management and maintenance from recent conferences through a collaborative arrangement. Accessing • Log into www.com Reference Features The Reference section of 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. including: • Select "Home" for general information • Select “Post Message” for posting new messages (i. creating topics) within conferences. 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 .com allows users to network with professionals by posting topics and replying to messages. e-mailing. • Select “More Options” for profiles.com Bulletin Board The Bulletin Board section of Turnaround-Network. • Select “Search Messages” for searching messages by key word or date.e. and messages.Turnaround-Network. • Messages Menu for listing messages.

Users can create topics within the conferences by posting a new message. 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 .Turnaround-Network. The Group Administrator creates the conferences within the Bulletin Board. 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. • Messages are posted and replied to within the topic area by the users.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.Turnaround-Network.e. • Topics are the next level message grouping within the Bulletin Board.com. As a registered user of Turnaround-Network.com • Conferences are the highest-level message grouping within the Bulletin Board.

Turnaround-Network. as appropriate © 2008 AP-Networks’ Proprietary All Rights Reserved 31 Reference Manual 01/08 . 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. 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. 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.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”. not anyone else’s • Edit the message.

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 .Turnaround-Network.

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

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

Sub-Components Communications Job Aids: Turnaround Meeting Guidelines Turnaround Work Process .com The capital project portfolio is a prioritized list of capital projects and plant modifications that clearly defines the specific value. and materials for each major category should also be included in the estimate. Conceptual Cost Estimate A Conceptual Cost Estimate is a deliverable of the Concept Phase.30 percent. this work includes all capital and expense activities planned and executed. 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. as well any additional activities added to the scope of work. and this component relates to the owner's contracting strategy and process for selecting contractors. Sub-Component Analysis: Communications .Pyramid Component Linkage Contractors Contractors play a critical role in the planning and execution of a Turnaround. Communications The appropriate communication of turnaround goals and progress to achieving these goals is essential to the success of Turnaround. The estimate should include Expense. Daily and weekly meetings to establish priorities and resolve issues must be well planned and disciplined to be effective. The accuracy of the estimate should be about +/.Pyramid Component Linkage Completed Turnaround Work A deliverable of the Turnaround Execution Phase. and prioritization of each project. Sub-Component Analysis: Contingency Planning . Also. 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.Sub-Components Contingency Planning Job Aids: Turnaround Work Process . 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. Communication between shifts and units that must be worked together are also important. the direct labor. payback. Maintenance Capital. For all high risk items contingency plans to appropriately deal with the risk should be established. indirect labor.Turnaround-Network. and Engineered Capital as major categories.

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

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

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

and Economic Decision Models. 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-Components Materials Management Job Aids: Procurement Management List Turnaround Work Process .Pyramid Component Linkage Long Range Plan Long range planning is the process for establishing Turnarounds based on Reliability Issues. Key part of this process is to understand previously encountered issues with improvement action items assigned to individuals with deadline dates for completion. critical requirements. Typically this should be projected for two to three Turnaround cycles. Contracts with all execution contractors and shops for component overhaul area also completed. cost. rationale. Capital Planning. and timing. Sub-Component Analysis: Long Range Plan . On-spec Production © 2008 AP-Networks’ Proprietary All Rights Reserved 39 Reference Manual 01/08 . work list criteria.com A systematic study of critiques of previous Turnarounds and large capital projects is an important element in the preparation for a successful Turnaround.Sub-Components Lessons Learned Job Aids: Capturing Lessons Learned Lessons Learned Action Item List Post-Turnaround Questionnaire Turnaround Work Process . At this phase the plan to control and distribute and stage the material is established. safety awareness. schedule. Sub-Component Analysis: Lessons Learned .Turnaround-Network. The Turnaround Team can effectively communicate to the organization the goals.Sub-Components Long Range Plan Job Aids: Turnaround Work Process . Materials Management During this Phase Materials are ordered and / or allocated and usually by equipment or project number with the computerized maintenance system. Sub-Component Analysis: Materials Management .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.Pyramid Component Linkage Objectives Letter The Turnaround Objectives Letter is a deliverable of the Concept Phase. list of major scope items.

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

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

Out and Personal Protective Equipment are determined.Scope Analysis. and capital projects.Scope Development Scope of Work . The scope includes all types of activities.com safety analysis is performed to establish appropriate safety procedures such as LockOut / Tag. execution.Pyramid Component Linkage Worklist Challenge Process Scope of Work-Analysis. During this phase the critical path and the manpower resources required to perform the work are typically determined. 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.. add-on work).Sub-Components Scheduling Practices Job Aids: Labor Hours Definition Milestone Schedule Checklist Turnaround Work Process .Turnaround-Network. Prioritization & Evaluation Scope of Work . including maintenance.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. Sub-Component Analysis: Safety Planning . & Evaluation © 2008 AP-Networks’ Proprietary All Rights Reserved 42 Reference Manual 01/08 . This date typically marks the end of the Definition Phase and results in a Frozen Worklist. inspections. 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. For a large Turnaround the scheduling is typically performed with a computerized Scheduling Program that allows " What If " type analysis. The schedule. must be able to be progressed in the field to establish proper control of the workflow. which is developed. Prioritization.g.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.Sub-Components Safety Planning Job Aids: Safety Plan Turnaround Work Process . and startup phases. Sub-Component Analysis: Scheduling Practices . Scope Freeze Date Scope freeze date is the date at which the final worklist is established.

cost.) Turnaround Start Date The turnaround start date is the date when the process shutdown begins. and timing in order for the turnaround to be viewed as successful. but should be stakeholders that are knowledgeable with the turnaround process and its key deliverables. Turnaround Performance Metrics Key performance metrics related to the turnaround outcomes (safety. 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.Sub-Components Training Job Aids: Turnaround Reference Booklet Guidelines Turnaround Work Process . They will not be involved in the day-to-day details of the planning and execution of the turnaround.Pyramid Component Linkage Turnaround Goals Turnaround goals are deliverables from the Long Range Strategy Phase of the work process. and operability). Operational and Maintenance training for new equipment or processes is also completed during this phase of the preparation process. actual freeze date versus planned. etc. This date also marks the beginning of the shutdown phase within the Turnaround Execution.Turnaround-Network. Integration of all work activities in one comprehensive scope document is believed to be essential. cost. This involves site specific safely training for all the workers as they are mobilized on site.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. and empowering the team to succeed. 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. Training A Training Plan for all necessary training including how and who will perform the Training is established. percent add-on work. © 2008 AP-Networks’ Proprietary All Rights Reserved 43 Reference Manual 01/08 .g. schedule. including the general scope. Sub-Component Analysis: Training . They are meant to capture the primary goals and outcomes of the turnaround. 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. as well as some of the practices (e.

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

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