Downstream

WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Table of Contents

1. PURPOSE.................................................................................................................
2. DETAILS..................................................................................................................
Step 7.5.1 - Approve and Communicate TA Execution Plan........................................4
Step 7.5.2 - Perform Pre-TA Execution Activities......................................................9
Step 7.5.3 - Conduct Pre-Activity Safety Review (for Shutting Down).......................18
Step 7.5.4 - Perform Plant Shutting Down Activities...............................................22
Step 7.5.5 - Perform TA Mechanical Days Activities................................................34
Step 7.5.6 - Conduct Pre-Activity Safety Review (for Startup)..................................45
Step 7.5.7 - Perform Pre-Startup and Startup Activities..........................................50
3. DOCUMENT HISTORY...............................................................................................

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

1. PURPOSE

The Plan & Execute Turnaround is one of the sub work process of Maintain Facility, under
Produce Product.

This document provides the details of steps involves in “7.5 Execute TA” stage.

Figure 1: Overview of Process Hierarchy for “7.5 Execute TA” stage

PETA workflow process diagram in Figure 1 indicates the general order of the steps
(WPL5). The steps can also be accomplished in parallel. Because of the interrelationships
of activities required in a well-planned turnaround, the TA Planning Schedule is more
appropriate tool to use for scheduling a specific turnaround.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

2. DETAILS

2.1 There are seven (7) key steps involved in “7.5 Execute TA” stage

Code No. Stage Description

7.5 Execute TA This stage describes key activities involved in

Pre-Execution and Execution of the turnaround
which comprises the following:

7.5.1 Approve and Communicate TA Execution

Plan.

7.5.2 Perform Pre-TA Execution Activities

7.5.3 Conduct Pre-Activity Safety Review (for

Shutting Down)

7.5.4 Perform Plant Shutdown Activities

7.5.5 Perform TA Mechanical Days Activities

7.5.6 Conduct Pre-Activity Safety Review (for

Startup)

7.5.7 Perform Pre- Startup and Startup Activities

Internal
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Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

2.2 The details of steps are tabulated as per the subsequent tables below.

Step 7.5.1 - Approve and Communicate TA Execution Plan

Description  This step describes the approval and communication of TA Execution

Plan (TEP). The TEP is approved after all the TEP related critical
findings from the TARR-3 assessment are closed.

The TIP communication ensures all stakeholders aligned on the TA

strategies, plans, methodologies, roles & responsibilities and other
key TA information towards achieving the TA Execution objectives
and KPI.

TA Execution Organization is officially formed during this step. The

time spent of its team members for TA activities shall follow the TA
Transition Plan as defined in the TEP.

Inputs  TEP and TEP Communication Pack for TARR-3 session.

 TEP related findings and mitigation plan from TARR-3.

Outputs  Approved TEP.

 Formation of TA Execution Team.

 Final TEP Communication Pack.

 TEP Communication Tracking (as per the TA Execution

Communication Plan defined in the TEP).

Key Responsibility Role Responsibility

TA Planning Lead  Update TEP based on TARR-3 findings

and submit for approval.
(Responsible for
initiation and  Update TEP Communication Pack as per
completion) the approved TEP.
 Organize and conduct TEP
Communication.

Internal
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Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Execution Lead  Form TA Execution Team.

 Support in TEP communication.

Maintenance TA  Coordinate and track TEP

Coordination Communication.
 Support in TEP communication.

Operation TA  Coordinate and track TEP Communication

Coordination specifically for Operation Department
including the shift team.
 Support in TEP communication.

TA Planning Team  Support in TEP communication

TA Operation  Support in TEP communication

Team

TA HSE Team  Support in TEP communication

TA Quality Team  Support in TEP communication

Procurement  Support in TEP communication

Representative

Site TA Committee  Approve TEP and support in TEP

communication

TA Scheduling  Report TEP Communication progress.

Process  Timeliness of TEP approval.

Measurement
 Timeliness of TA Execution Team formation.

 Timeliness of TEP communications and engagements.

Guidance TA Execution Plan

The final TEP contents can be referred as follows:

 TA Premise (latest update) – refer to step “7.1.3 Establish TA

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Master Plan”.

 TA Execution KPI and its definition (latest update) – refer to

step “7.2.1 Develop TA Implementation Plan”.

o TA HSE KPI.

o TA Quality KPI.

o TA Execution Schedule KPI.

o TA Cost KPI.

o TA Operation KPI.

 TA Worklist Summary including latest and approved TA AWR

and LWR Worklist – refer to step “7.3.2 Optimize and Approve
TA Worklist”.

 TA Execution Organization – refer to step “7.4.1 Develop TA

Execution Plan”.

 TA Systemization Strategy and Schedule (latest update) – refer

to step “7.2.2 Develop and Implement TA Operation Plan”.

 TA Execution High-Level Schedule (latest update) – refer to

step “7.2.8 Establish TA Memorandum”.

 Pre-TA Execution and Post TA Execution Milestones – refer to

step “7.3.7 Develop TA Execution Schedule”.

 TA Resource Loading Plan – refer to step “7.4.3 Integrate TA

Execution Schedule”.

 DOSH Strategy (latest update) – refer to step “7.2.1 Develop

TA Implementation Plan”.

 EWR process – refer to step “7.3.2 Optimize and Approve TA

Worklist”.

 Emergent Material and Service Requisition Process – refer to

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

GP work processes and procedures.

 TA Material Handling Process – refer to step “7.4.6 Receive and

Manage TA Materials”.

 TA Contract Change Order Management – refer to step “7.4.4

Manage TA Contracts”.

 List of TA Contractors, scope and target mobilization date –

refer to step “7.4.4 Manage TA Contracts”.

 List of TA Project Contractors, scope and target mobilization

date (latest update) – refer to step “7.2.3 Develop and
Implement TA Project Plan”.

 TA Logistic Plan - refer to step “7.4.2 Perform TA Detailed

Planning”.

 TA PTW Plan - refer to step “7.4.2 Perform TA Detailed

Planning”.

 TA HSE Plan (only include the detailed requirements, plans and

programs specific for TA Execution phase) – refer to step “7.2.1
Develop TA Implementation Plan”.

 TA Quality Plan (only include the detailed requirements, plans

and programs specific for TA Execution phase) – refer to step
“7.2.1 Develop TA Implementation Plan”.

 TA Operation Plan (only include the detailed requirements,

plans and programs specific for TA Execution phase) – refer to
7.2.2 Develop and Implement TA Operation Plan.

 TA Project Plan (if required) – refer to PPMS.

 TA Strategy (specific for TA Execution only) – refer to step

“7.1.3 Establish TA Master Plan”.

 TA Key Risks and Success Factors (latest update from TA

Governance Risks Register) – refer to step “7.2.7 Conduct TA

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Risk Assessment”.

 TA Information Management & Control Plan (latest update and

specific for TA Execution only) – refer to step “7.2.1 Develop TA
Implementation Plan”.

 TA Execution Communication Plan – refer to step “7.4.1

Develop TA Execution Plan”.

 TEP Communication Pack

TEP Communication Pack summarizes the TEP contents for

communication to all the stakeholders as identified in TA Execution
Communication Plan in the TIP. The TA Execution Communication
also specifies the methodology, timing and information to be
communicated. Not all stakeholders require the full information of
the TIP contents.

Information  MyExplorer
Technology Tools
 MyEvents

 OPU Intranet

 Primavera

Reference  Not applicable.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Step 7.5.2 - Perform Pre-TA Execution Activities

Description This step describes implementation of Pre-TA Execution activities to

completed before the plant shutting down in accordance Pre-TA
Execution Schedule, TA Job Packages, TA Execution Plan (TEP) and
other related strategies and plans developed to support the activities.

The Pre-TA Execution should be scheduled, tracked and discussed on a

regular basis for timely completion and minimize interference with
daily plant operational activities.

Inputs  Approved TEP.

 TA Operation Planning Deliverables.

 TA Project Planning Deliverables.

 Pre-TA Execution Schedule.

 TA Job Packages.

 TA Resource Loading Plan.

 Overall TA Risk Register (open mitigation plan/action items).

Outputs  Pre-TA Execution Activities (as defined in Pre-TA Execution Schedule)

completed.

 Overall Pre-TA Execution Progress Report.

 Updated DOSH Inspection Strategy, if required.

 Closure of all TA Governance Mitigation Plan from TA Risk Register

with due date before TA Execution.

Key
Responsibility Role Responsibility

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Planning Lead  Lead the overall Pre-TA Execution activities.

(Responsible for  Participate in DOSH Engagement.

initiation and
completion)

TA Execution Lead  Lead TA Job Package Handover activities.

 Participate in DOSH Engagement.

 Lead TA Execution Organization in

implementing Pre-TA Execution activities.

Maintenance TA  Coordinate the overall Pre-TA Execution

Coordination activities.

TA Scheduling  Produce Pre-TA Execution Progress Report.

 Monitor and control Pre-TA Execution

Schedule and act on issues.

 Produce report on PASR-SD and TA Risk

Register mitigation plan closure status.

TA Planning Team  Perform TA Job Package handover.

 Collect feedback from JAF and update TA

Job Package.
 Reissue TA Job Package after update.

 Support other team in implementing Pre-TA

Execution activities.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Execution  Receive TA Job Package

Discipline Team
 Perform TA Joint Walkabout, Site Tagging
and update Job Audit Form (JAF).

 Attend TA trainings.

 Conduct TA Assistants and Contractor

familiarization / orientation program.
 Supervise Pre-TA Execution fabrication
work.
 Perform equipment inspection.

 Support other team in implementing Pre-TA

Execution activities.

Site Operation Lead  Lead Operation-related TA Pre-Execution

activities as per TA Operation Planning.

 Support other team in implementing Pre-TA

Execution activities.

Operation TA  Evaluate priority to resolve conflict between

Coordination implementation of Pre-TA Execution
activities and daily plant operation.
 Coordinate Operation related TA trainings.

 Coordinate scaffolding erection and

insulation removal.

 Coordinate TA Joint Walkabout and site

tagging.

 Support other team in implementing Pre-TA

Execution activities.

TA Operation Team  Receive TA Job Package.

 Perform TA Joint Walkabout, Site Tagging

and update Job Audit Form (JAF).
 Support other team in implementing Pre-TA
Execution activities.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Service Provider  Receive TA Job Package.

 Perform TA Joint Walkabout, Site Tagging

and update Job Audit Form (JAF).

 Set-up TA Village and other temporary

facilities.

 Assign manpower for screening and

registration.

 Attend TA trainings.

 Perform equipment mobilization and

laydown at site.
 Perform scaffolding erection.

 Perform insulation removal.

 Perform Pre-TA Execution fabrication work.

 Provide support the implementing Pre-TA

Execution activities.

TA Logistics Planning  Coordinate TA Village and other temporary

and Coordination facilities setting-up activities.

 Coordinate manpower mobilization.

 Coordinate equipment mobilization,

inspection and laydown at site.
 Support other team in implementing Pre-TA
Execution activities.

Site HSE Lead  Lead HSE-related TA Pre-Execution

activities.
 Support other team in implementing Pre-TA
Execution activities.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA HSE Planning and  Coordinate HSE screening

Coordination
 Coordinate manpower registration and
Safety Passport issuance.

 Coordinate HSE-related TA trainings,

certification and familiarization.

 Support other team in implementing Pre-TA

Execution activities.

TA HSE Team  Conduct HSE screening.

 Implement manpower registration and

Safety Passport issuance.
 Conduct or facilitate HSE-related TA
trainings, certification and familiarization.
 Participate in DOSH Engagement, as
nominated.
 Support other team in implementing Pre-TA
Execution activities.

Site Quality Lead  Lead Quality-related TA Pre-Execution

activities.
 Support other team in implementing Pre-TA
Execution activities.

TA Quality Planning  Coordinate technical screening (CCA, CIDB,

and Coordination welders, etc.)
 Coordinate Quality-related TA trainings,
certification and familiarization.
 Coordinate procedure review and approval.

 Support other team in implementing Pre-TA

Execution activities.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Quality Team  Conduct technical screening (CCA, CIDB,

welders, etc.).
 Conduct or facilitate Quality-related TA
trainings, certification and familiarization.
 Participate in DOSH Engagement, as
nominated.
 Support other team in implementing Pre-TA
Execution activities.

Inspection TA  Coordinate TA Inspection Team to perform

Coordination inspection activities during Pre-TA
Execution.

 Coordinate DOSH Engagement.

 Support other team in implementing Pre-TA

Execution activities.

TA Project Planning  Perform Project-related Pre-TA Execution

and Coordination activities.
 Support other team in implementing Pre-TA
Execution activities.

TA Governance  Implement mitigation plan timely to close

Actionee all the action items from TA Governance
Risk Register with due date before TA
Execution.

Site TA Committee  Monitor Pre-TA Execution progress and

intervene as necessary.
 Participate in DOSH Engagement, as
nominated.

Process  Timely completion of Pre-TA Execution activities as per schedule.

Measurement
 TA HSE KPI.

 TA Quality KPI.

Guidance Pre-TA Execution Activities

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Pre-TA Execution activities must be implemented, monitored and

completed prior to step “7.5.3 Conduct Pre-Activity Safety Review (for
Shutting Down)”. The Pre-TA Execution activities typically involve the
followings:

 TA Job Packages Handover:

o Handover and expectation briefing sessions.

o TA Joint Walkabout (Contractor, Operation and TA Team) to

validate the Job Package Planning and capture improvements in
the JAF.

o Update changes from JAF and reissue the TA Job Package.

 TA Village and temporary facilities setup:

o Setup TA Village and Gate Access System

o Setup on-site temporary facilities (cabins, rest shelter, toilets,

drinking station, etc.)

 Manpower screening, registration and mobilization:

o Work permit or visa clearance for foreign workers.

o Welders qualification (as per WPS, PQR and WQT)

o CCA and CIDB screening.

o HSE screening and heath check.

o Mandatory HSE training attendance.

o Gate Access System registration and Safety Passport issuance.

 Training, certification and familiarization implementation.

o Quality training.

o Operation training.

Internal
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Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

o Other HSE training.

o TA Assistants and Contractor familiarization / orientation

program.

 Equipment mobilization, inspection and laydown at site.

 Scaffolding erection

 Insulation removal.

 Site tagging (for EIS/SIS/BLIS, JIT, defect, etc.).

 Review and approval of internal procedures.

 Pre-TA Execution fabrication work:

o Material issuance for fabrication.

o Fabrication work as per the fabrication and repair procedure.

o Inspection as per ITP.

 DOSH Engagement:

o Update and finalize DOSH Inspection Strategy and inspector

loading, if required.

o Approval of DOSH documents:

 DOSH registered equipment repair and fabrication procedure

(including hydrostatic test waiver document, if required).

 Confined Space Entry notification.

 Engineering Construction Work notification (i.e. JKJ 103).

 New scaffolding design.

 Crawler Crane, Mass Climber set-up, etc.

 Closure of TA Governance Risk Register mitigation plan for all action

items with due date before TA Execution.

Internal
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Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Information  Primavera
Technology
 STEPS
Tools

Reference  Pre-TA Execution Schedule template.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Step 7.5.3 - Conduct Pre-Activity Safety Review (for Shutting

Down)
Description This step describes implementation of Pre-Activity Safety Review for
Plant Shutting Down (PASR-SD) to evaluate risk and readiness to
safely shutdown the plant and handover for TA Mechanical Days
activities. PASR-SD “High” findings are required to be closed before
the start of plant shutting down process.

Inputs  Approved TEP.

 Approved TIP.

 TA Operation Planning Deliverables.

 TA Project Planning Deliverables.

 TA Planning Schedule Progress Report.

 Pre-TA Execution Schedule Progress Report.

 TA Job Packages.

 Integrated TA Execution Master Schedule.

 TA Resource Loading Plan.

 Overall TA Risk Register.

Outputs  PASR-SD conducted.

 PASR-SD Report.

 PASR-SD “High” findings and mitigation plan closed.

Key Role Responsibility

Responsibility
Site PASR Lead  Form TA PASR-SD Team
(Responsible for  Lead PASR-SD activity and facilitate the
initiation and session.
completion)
 Review PASR-SD report.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA PASR  Coordinate PASR-SD activity.

Coordination
 Capture PASR-SD findings and develop
PASR-SD Report.

 Consolidate PASR-SD Findings and

Mitigation Plan into an Overall TA Risk
Register.
 Monitor, track and follow-up PASR-SD
findings closure status.

TA PASR Team  Conduct PASR-SD activity.

Site Operation Lead  Participate in PASR-SD activity.

 Endorse PASR-SD Report.

 Evaluate PASR-SD findings and approve to

proceed to the next step.

Plant Start Up /  Participate in PASR-SD activity.

Shutdown
 Review PASR-SD Report.
Coordination

Operation TA  Participate in PASR-SD activity.

Coordination
 Review PASR-SD Report.

TA Execution Lead  Participate in PASR-SD activity.

 Review PASR-SD Report.

TA Planning Lead  Participate in PASR-SD activity.

 Review PASR-SD Report.

TA Execution  Participate in PASR-SD activity, if required.

Coordination Team

TA Operation Team  Participate in PASR-SD activity, if required.

TA HSE Team  Participate in PASR-SD activity, if required.

TA Quality Team  Participate in PASR-SD activity, if required.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Execution  Participate in PASR-SD activity, if required.

Discipline Team

TA Planning Team  Participate in PASR-SD activity, if required.

TA Governance  Implement mitigation plan timely to close

Actionee PASR-SD ‘High’ findings

Site TA Committee  Participate in PASR-SD activity, if required.

 Monitor PASR-SD Findings and Mitigation

Plan Closure Progress and intervene as
necessary.

TA Scheduling  Produce PASR-SD Findings and Mitigation

Plan Closure Status Report.

Process  Timeliness of PASR-SD activity and report.

Measurement
 Timeliness of PASR-SD Risk Mitigation Plan action items closure.

Guidance Pre-Activity Safety Review for Plant Shutdown (PASR-SD)

PASR-SD is a process to evaluate plant risks and readiness to perform

plant shutting down activities. PASR-SD findings (or punch-list) are
categorized as follow:

 “High” findings (i.e. punch-list “A”) - to be closed before plant

shutting down.

 “Medium” findings (i.e. punch-list “B”) - to be closed before TA

Mechanical Days start.

 “Low” findings (i.e. punch-list “C”) - to be closed during post-TA

Execution.

It is recommended that the Site TA Committee to evaluate pending

PASR-SD findings before proceeding to the next step.

Information  STEPS
Technology

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Tools

Reference  PASR-SD procedure and Assessment template.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Step 7.5.4 - Perform Plant Shutting Down Activities

Description This step describes the implementation of plant shutting down

activities to ensure the plant, system and equipment are in safe
condition, free of energies and hazardous substances to minimize risk
exposure before Safe Handover for TA Mechanical Days activities.

The shutting down activities include:

 “First Product Off” indicating the start of P2P duration and TA

Execution period.

 Implementation of Plant Shutting Down activities.

 Initiation of TA Execution Coordination Meeting.

 Declaration of TA LWR Worklist Freeze Date.

 Initiation of TA Emergent Work Request (EWR) registration process.

 Implementation of Safe Handover of system package or equipment.

Inputs  Approved TEP.

 TA Operation Planning Deliverables.

 TA Project Planning Deliverables.

 Integrated TA Execution Master Schedule and TA Systemization

Schedule.

 TA Job Packages.

 Pre-TA Execution Activities (as defined in Pre-TA Execution

Schedule) completed.

 PASR-SD “High” findings closed.

 Closure all the action items from TA Governance Risk Register with
due date before TA Execution.

Outputs  “First Product Off” date and time captured.

 Communication to all stakeholders on the start of P2P duration and

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Execution period.

 Isolation, de-energizing and LOTO implementation completed.

 TA LWR Worklist Freeze Date and TA EWR Registration Process Start

Date communicated and implemented.

 TA EWR Worklist Register and Tracking.

 Manual Confirmation Order (MCO) list.

 TA Execution Coordination Meeting started.

 PASR-SD “Medium” findings and mitigation plan closed.

 System or Equipment Handover completed and communicated.

 TA Execution Progress Report and Look-Ahead Schedule.

 TA Resource Loading Plan vs. Actual Report.

Key
Responsibility Role Responsibility

Site Operation Lead  Lead the overall Plant Shutting Down

activities.
(Responsible for
initiation and  Chair TA Coordination Meeting during Plant
completion) Shutting Down period.

 Initiate Feed Cut-Off

 Capture “First Product Off” date and time

and communicate.
 Evaluate PASR-SD findings and approve to
proceed to the next step.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Scheduling  Produce overall Daily TA Execution Progress

and TA KPI Status Report.
 Monitor and analyze scheduling data and
actual Plant Shutting Down activities
progress against the Integrated TA
Execution Master Schedule.
 Produce report on Safe Handover status.

 Facilitate TA Execution Coordination

Meeting.

 Monitor daily actual resources loading

against plan and produce report.

 Develop TA Schedule KPI intervention plan

(i.e. Delay Recovery Plan), if required.

Plant Start Up /  Coordinate Plant Shutting Down activities

Shutdown as per the Integrated TA Execution Master
Coordination Schedule.
 Manage LOTO for Safe Handover.

 Manage Master Blind list, blinding activities

and changes in blinding requirements.

 Coordinate the intervention plan and

resolves issues during Plant Shutting Down
period, if required.

TA Operation Team  Execute Plant Shutting Down as per the

Integrated TA Execution Master Schedule.
 Manage and supervise Service Provider’s
resources for Plant Shutting Down
activities.

 Implement the intervention plan and

resolves issues during Plan Shutting Down
period, if required.
 Evaluate PASR-SD findings and approve to
proceed to the next step.

Internal
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WORK PROCESS
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Operation TA  Track completion of Plant Shutting Down

Coordination activities for each equipment or system
package.

 Coordinate and communicate Safe

Handover for equipment or system package
from Operation to TA Execution Team.
 Screen the submitted TA EWR Worklist and
assign priority.
 Assign TA EWR Worklist with Process
System information.

TA Execution Lead  Declare and communicate the start of P2P

duration and TA Execution period to all
stakeholders.

 Form and lead Plant Start Up / Shutdown

Team.

 Monitor and support the overall Plant

Shutting Down activities.

 Review TA EWR Worklist.

TA Execution  Coordinate support for the overall Plant

Coordination Team Shutting Down activities.

Plant Start Up /  Troubleshoot and execute corrective

Shutdown Team maintenance during Plant Shutting Down
activities.

 Manage and supervise Service Provider’s

resources to support the overall Plant
Shutting Down activities.

TA Execution  Support the overall Plant Shutting Down

Discipline Team activities as per assigned role.
 Support TA EWR Worklist Planning.

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WORK PROCESS
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Service Provider  Execute Battery Limit Isolation (BLIS) and

System Isolation (SIS).
 Provide support resources (manpower,
equipment, material, etc.) for the overall
Plant Shutting Down activities.

 Plan the approved TA EWR Worklist.

TA Planning Lead  Form and lead TA Execution Control and

Support Team.
 Monitor and support the overall Plant
Shutting Down activities.

Emergent TA Work  Communicate and declare TA LWR Worklist

Coordination Freeze Date.
 Initiate TA EWR Worklist Registration
Process.
 Screen the submitted TA EWR Worklist for
completeness and accuracy of scope.
 Register, plan and track TA EWR Worklist.

TA Worklist  Evaluate emerging TA scope and submit TA

Originating EWR Worklist with detailed scope
definitions.

TA Worklist  Evaluate and approve TA EWR Worklist.

Approving

Site HSE Lead  Lead HSE-related Plant Shutting Down

activities.

TA HSE Planning  Coordinate TA HSE programs, activities,

and Coordination walkabouts and audits as per TA HSE Plan.
 Capture and report TA HSE KPI.

 Analyze HSE data and findings information.

 Produce TA HSE KPI intervention plan, if

required.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA HSE Team  Implement TA HSE programs, activities,

walkabouts and audits as per TA HSE Plan.
 Monitor TA Execution activities and ensure
compliance to TA HSE Plan.

Site Quality Lead  Lead Quality-related Plant Shutting Down

activities.

TA Quality Planning  Coordinate TA Quality programs, activities,

and Coordination walkabouts and audits as per TA Quality
Plan.

 Capture and report TA Quality KPI.

 Analyze Quality data and findings

information.
 Produce TA Quality KPI intervention plan, if
required.

TA Quality Team  Coordinate JIT activities on Battery Limit

and System Isolation joints.
 Implement TA Quality programs, activities,
walkabouts and audits as per TA Quality
Plan.

 Monitor TA Execution activities and ensure

compliance to TA Quality Plan.

TA Project Planning  Coordinate and execute TA Project activities

and Coordination during Plant Shutting Down period as per
Integrated TA Execution Master Schedule.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Logistics  Coordinate equipment resources

Planning and movement, inspection and site laydown.
Coordination
 Manage TA Village and Temporary
Facilities.
 Capture and monitor actual resources
(manpower and equipment) loading and
worker’s productivity data.

 Coordinate logistics support during Plant

Shutting Down period including for EWR.

TA Contract  Monitor contractors’ performance.

Controlling and
 Coordinate EWR services procurement and
Coordination
contractors’ workers’ mobilization.
 Support EWR services scope planning.

TA Cost Controlling  Support in obtaining EWR approval.

 Track and manage EWR cost versus budget.

 Track and report TA Cost KPI.

TA Material  Coordinate material issuance for work

Controlling and execution.
Coordination
 Support EWR material planning.

 Coordinate EWR materials procurement,

receipt, inspection and storage.

 Monitor and support in EWR material

tracking and expediting.

TA Material and  Procure and award EWR services.

Services
 Procure, track and expedite EWR materials
Procurement
until delivery.
 Manage Criticism of Material (COM).

TA Material  Manage EWR materials delivery and receipt.

Handling

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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA PASR  Monitor, track and follow-up PASR-SD

Coordination findings closure status.

TA Governance  Implement mitigation plan timely to close

Actionee PASR-SD “Medium” findings before TA
Mechanical Days start.

Site TA Committee  Evaluate and endorse “First Product Off”

date and time.

 Monitor Plant Shutting Down progress and

intervene as necessary.

 Provide directive, evaluate issues and

propose way forward.

Process  TA HSE KPI.

Measurement
 TA Quality KPI.

 TA Execution Schedule KPI.

 TA Cost KPI.

 Timeliness of Safe Handover progress.

 % of TA EWR Worklist from the total TA Worklist.

 Timely EWR approval.

 Timeliness of PASR-SD Risk Management Plan action items closure.

Guidance Plant Shutting Down

Plant Shutting Down activities are critical to ensure safe

decommissioning and timely delivery of the plant, system, piping and
equipment for the start of Mechanical Days activities free of energies
and uncontrolled hazard.

The activities include:

 Installation of temporary line, hoses, containers and utilities

support.

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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

 Initiation of plant feed cut-off and “First Product Off”.

 Formation Plant Shutdown Support Team to support TA Operation

Team to safely delivering the plant.

 Initiate TA Execution Coordination Meeting.

 Management, tracking and reporting of TA lagging and leading KPI:

o TA HSE KPI and manhours.

o TA Quality KPI.

o TA Schedule KPI.

o TA Cost KPI.

o Daily TA Execution Progress Report.

 Stopping of machines and equipment.

 Proper equipment and piping draining, emptying, purging, venting,

flushing and clearing.

 Depressurizing and cooling down.

 Waste and effluent management.

 Chemical cleaning, decontamination and industrial hygiene

monitoring.

 Implementation of Battery Limit Isolation (BLIS) and System

Isolation (SIS)

 Proper Locked Out Tagged Out (LOTO) Management and Blind

Management.

 Plant Shutdown Support Team to provide maintenance support

during shutting down activities.

 Closure of PASR-SD ‘Medium’ findings.

It is a good HSE practice to have a “black-out day” at a specified time

during Plant Shutting Down period which allow only authorized

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WORK PROCESS
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

personnel inside the plant site to minimize exposure to the hazardous

conditions.

First Product Off

“First Product Off” is the date and time the first main plant product
being out of production to indicate the start of P2P duration and TA
Execution period. The “First Product Off” must be clearly captured and
communicated to all stakeholders and the workforce involved.

Safe Handover

Safe Handover indicates the completion of all plant shutting down and
de-commissioning activities for each system package or equipment as
specified in TA Systemization to safely move to step “7.5.4 Perform
Mechanical Days Activities”. Typically, it shall be managed through
closure of all PASR-SD “Medium” findings and Hand-Over of
Equipment for Maintenance (HOEM) certification from Operation to TA
Execution Team.

TA LWR Worklist Freeze Date

TA LWR Worklist Freeze Date defines the last date for submission and
registration of the TA LWR Worklist which is declared at the start of
P2P duration and TA Execution period.

TA EWR Worklist registration process

TA EWR Worklist Registration Process commences after TA LWR Freeze

Date. Similar to the TA LWR worklist, the TA EWR will have minimum
planning mainly on defining the right scope and securing the material
and services (based on GP work processes and procedures for

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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Emergent Procurement Process such as Manual Confirmation Order,

etc.).

The procurement of services is typically under lump sum price for all
the services rendered to execute the work (but the basis for cost
estimates can be from the available unit rates). The cost impact of the
EWR also must be closely monitored against allocated budget due to
additional cost to expedite the material and services.

Typically, the EWR worklist will only be scheduled independent if it

deemed to be critical. The schedule will not be integrated with the
Integrated TA Execution Master Schedule unless it is ‘must’ with
appropriate approval and change management process. Therefore, it is
really critical to minimize the TA EWR Worklist by having a more
stringent screening and approval process.

There are 5 types of EWR similarly to LWR:

 New Scope.

 Scope Change on existing TA Worklist.

 Scope Reassign to Daily Maintenance.

 Scope Postpone to next the TA.

 Scope Deleted.

Any critical TA worklist falls under re-assign, postpone or delete

category shall be accompanied with risk assessment to evaluate the
risk of not implementing the scope, delaying the implementation or
implementing it in daily maintenance.

The registered TA EWR Worklist scope must be adequately defined,

and scope must be registered by each equipment identification tag
(i.e. blanket registration of multiple equipment tag or scope in a single
EWR is not allowed and shall the process system).

Information  Primavera

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Technology
Tools

Reference  Plant Policy, Work Processes and Procedures (Operation, HSE,

Maintenance, etc.)

 PASR-SD procedure and Assessment template.

 PETRONAS BFJI procedure and form.

 GP work processes and procedures.

 LOTO procedure.

 Blinding Management procedure and Tracking template.

 EWR procedure and template.

 System Handover procedures and certificate template (i.e. HOEM).

 Daily TA Execution Progress Report template.

 OFWP.

 EMWP.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Step 7.5.5 - Perform TA Mechanical Days Activities

Description  This step describes the implementation of TA Mechanical Days activities

which shall be performed safely and efficiently in accordance to the TA
Job Packages, Integrated TA Execution Master Schedule and TA
Execution Plan (TEP).

Inputs  Approved TEP.

 TA Operation Planning Deliverables.

 TA Project Planning Deliverables.

 Integrated TA Execution Master Schedule and TA Systemization

Schedule.

 TA Resource Loading Plan.

 TA Job Packages.

 Plant Shutting Down activities completed.

 Isolation, de-energizing and LOTO implementation completed.

 System or Equipment Handover completed and communicated.

 Plant PTW process and procedures.

 PASR Shutdown (PASR-SD) “Medium” findings closed.

Outputs  TA Execution plans and program (as defined in TEP) implemented.

 TA Mechanical Days activities completed (as defined in TA Job

Package and Integrated TA Execution Master Schedule).

 Maintenance, reliability and equipment integrity data and abnormality

findings captured in test report and PPM check-sheets.

 TA EWR Worklist implemented and completed.

 TA KPI tracked and reported.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

 TA Execution Progress Report and Look-Ahead Schedule.

 TA information and data are analyzed and reported, and actions are
taken to mitigate issues.

 Job Audit Form (JAF) is filled-up to capture inconsistency and

improvements to the TA Job Package and planning documents.

 All WCS and JICS signed and completed (except for SIS and BLIS de-
blinding work).

 TA EWR Worklist Register and Tracking.

 Manual Confirmation Order (MCO) list.

 PTW issuance and closure tracking.

Key
Responsibility Role Responsibility

TA Execution Lead  Lead the overall TA Mechanical Days

activities.
(Responsible for
initiation and  Lead the implementation of TEP plans and
completion) programs.

 Facilitate Site TA Committee Meeting.

 Review EWR.

TA Planning Lead  Lead TA Execution Control and Support

Team to monitor and control TA Execution
Schedule and provide Logistics and EWR
support.

 Capture the official first and last Mechanical

Days date and time and communicate to all
stakeholders and workforce.
 Review EWR.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Scheduling  Produce overall Daily TA Execution Progress

and TA KPI Status Report.
 Facilitate TA Execution Coordination
Meeting.
 Analyze and report actual resources loading
and worker’s productivity against plan.
 Monitor and analyze scheduling data and
actual TA Mechanical Days activities
progress against the Integrated TA
Execution Master Schedule.
 Develop TA Schedule KPI intervention plan
(i.e. Delay Recovery Plan), if required.

TA Execution  Coordinate TA Mechanical Days activities to

Coordination Team ensure timely execution as per the
Integrated TA Execution Master Schedule.

 Coordinate the intervention plan and

resolves issues during TA Mechanical Days
period, if required.

TA Execution  Implement TA Mechanical Days activities to

Discipline Team ensure timely execution as per the
Integrated TA Execution Master Schedule.

 Manage and supervise Service Provider’s

resources for TA Mechanical Days activities.

 Capture maintenance, reliability and

equipment integrity data and abnormality
findings in test report and PPM check-
sheets.

 Fill-up Job Audit Form in the TA Job

Packages to capture inconsistency and
improvement required to the TA Planning.
 Support TA EWR Worklist planning and
manage the execution.
 Implement the intervention plan and
resolves issues during TA Mechanical Days
period, if required.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Emergent TA Work  Screen the submitted TA EWR Worklist for

Coordination completeness and accuracy of scope.
 Register and track TA EWR Worklist.

 Coordinate planning and execution of the

approved TA EWR Worklist for completion
before TA Mechanical Days end.

TA Worklist  Evaluate abnormality and emerging TA

Originating scope and submit TA EWR Worklist with
detailed scope definitions.

TA Worklist  Evaluate and approve TA EWR Worklist.

Approving

Service Provider  Execute TA Mechanical Days activities.

 Provide adequate resources (manpower,

equipment, material, etc.) as per Resource
Loading Plan.

 Plan and execute the approved TA EWR

Worklist as per the agreed scope.

 Support in capturing maintenance,

reliability and equipment integrity data and
abnormality findings in test report and PPM
check-sheets.

 Support in filling-up Job Audit Form (JAF)

to capture inconsistency and improvement
required to the TA Planning.
 Implement the intervention plan and
resolves issues during TA Mechanical Days
period, if required.

Site Operation Lead  Monitor and support the overall TA

Mechanical Days activities.

 Track and manage PTW issuance and

closure.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Operation TA  Coordinate Operation activities as per the

Coordination Integrated TA Execution Master Schedule.
 Track completion of TA Mechanical Days
activities for each equipment or system
package.

 Screen the submitted TA EWR Worklist and

assign priority.

 Assign TA EWR Worklist with Process

System information.

Plant Start Up /  Manage Master Blind list, blinding activities

Shutdown and changes in blinding requirements.
Coordination

TA Operation Team  Issue and approve PTW as per PTW Plan

ensure compliance.
 Support and monitor TA Mechanical Days
activities to ensure safe execution.
 Track PTW issuance and closure.

Site HSE Lead  Lead the implementation of TA HSE

programs, activities, walkabouts and audits
as per TA HSE Plan.

TA HSE Planning  Coordinate TA HSE programs, activities,

and Coordination walkabouts and audits as per TA HSE Plan.
 Track and report TA HSE KPI status.

 Capture TA HSE findings and data.

 Analyze HSE data and findings information.

 Produce TA HSE KPI intervention plan, if

required.

TA HSE Team  Implement TA HSE programs, activities,

walkabouts and audits as per TA HSE Plan.

 Monitor TA Execution activities and ensure

compliance to TA HSE Plan.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Quality Planning  Coordinate TA Quality programs, activities,

and Coordination walkabouts and audits as per TA Quality
Plan.

 Track and report TA Quality KPI status.

 Capture TA Quality findings and data.

 Produce TA Quality KPI intervention plan, if

required.

TA Joint Integrity  Coordinate JIT programs, activities,

Planning and walkabouts and audits as per TA Quality
Coordination Plan
 Capture and report on JIT progress and
status.
 Analyze JIT data and findings information.

 Produce JIT intervention plan, if required.

Site Quality Lead  Lead the implementation of TA Quality

programs, activities, walkabouts and audits
(including JIT programs and activities) as
per TA Quality Plan.

TA Quality Team  Implement TA Quality programs, activities,

walkabouts and audits (including JIT
programs and activities) as per TA Quality
Plan.
 Ensure WCS and JICS are signed as per the
process and completed as required.
 Monitor TA Execution activities and ensure
compliance to TA Quality Plan.

TA Project Planning  Coordinate and execute TA Project activities

and Coordination during TA Mechanical Days period as per
Integrated TA Execution Master Schedule.

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Logistics  Coordinate equipment resources

Planning and movement, inspection and site laydown.
Coordination
 Manage TA Village and Temporary
Facilities.
 Capture and monitor actual resources
(manpower and equipment) loading and
worker’s productivity data.

 Coordinate logistics support during TA

Mechanical Days period including for EWR.

TA Contract  Monitor contractors’ performance during TA

Controlling and Execution.
Coordination
 Coordinate EWR services procurement and
contractors’ workers’ mobilization.

 Support EWR services scope planning.

TA Budget Planning  Support in obtaining EWR approval.

and Cost Controlling
 Track and manage EWR cost versus budget.

 Track and report TA Cost KPI.

TA Material  Coordinate material issuance for work

Controlling and execution.
Coordination
 Support EWR material planning.

 Coordinate EWR materials procurement,

receipt, inspection and storage.
 Monitor and support in EWR material
tracking and expediting.

TA Material and  Procure and award EWR services.

Services
 Procure, track and expedite EWR materials
Procurement
until delivery.

 Manage Criticism of Material (COM).

TA Material  Manage EWR materials delivery and receipt.

Handling

Internal
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WORK PROCESS
Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Site TA Committee  Discuss and endorse First and last TA

Mechanical Days date and time.
 Monitor Plant Shutting Down progress and
intervene as necessary.
 Provide directive, evaluate issues and
propose way forward during TA Execution.

Process  TA HSE KPI.

Measurement
 TA Quality KPI.

 TA Execution Schedule KPI.

 TA Cost KPI.

 % of TA EWR Worklist from the total TA Worklist.

 Timeliness of EWR approval.

 Timeliness of PTW issuance and closure.

Guidance  TA Mechanical Days Activities

 Activities during TA Mechanical Days must be implemented in safe and

efficient manners. The activities include but not limited to:

 Implementation of plans and programs as defined in TEP covering:

o HSE plan and programs.

o Quality plan and programs.

o Logistic plan,

o PTW plan, etc.

 Implementation of TA Mechanical Days activities as defined in the

TA Job Package and Integrated TA Execution Master Schedule.

o Maintenance activities.

o Operations activities.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

o Inspection activities.

o Project activities.

o Capturing maintenance, reliability and equipment integrity data

and abnormality findings in test report and PPM check-sheets.

o Implementation and completion of WCS and JICS as per the

sequence and timing as specified in TA Quality Plan.

 TA EWR Worklist are timely managed, registered, screened, tracked,

planned, implemented and completed.

 Management, tracking and reporting of TA lagging and leading KPI:

o TA HSE KPI and manhours.

o TA Quality KPI.

o TA Schedule KPI.

o TA Cost KPI.

o Daily TA Execution Progress Report.

 Analysis of TA performance data and findings information:

o HSE performance and findings.

o Quality performance and findings

o EWR cost.

o Integrated TA Execution Master Schedule and work progress:

 Plan vs actual S-curve.

 Negative variance reporting, delay analysis and recovery plan.

 Look-ahead schedule and plan.

 TA Systemization Schedule progress and completion.

 Contractor Resources Loading Plan versus Actual.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

 Contractor Productivity.

o PTW management, issuance, closure and tracking as per TA PTW

Plan.

o Fill-up Job Audit Form (JAF) attached in each TA Job Packages to

capture the following improvements to the TA Job Package and
planning documents:

 Inconsistency or incomplete compare with the actual

implementation (tasks, duration, resources, materials, etc.).

 Inconsistency compare with the actual site conditions or

installations.

 Wrong specifications of equipment or materials.

 Missing or wrongly specified job hazards.

 Not enough attachment of technical documents.

o Issues are captured and managed, and action items are

implemented to mitigate the issues.

 TA Execution Meetings:

o Site TA Committee Meeting (i.e. TA Execution Leadership

Committee Meeting and TA Technical Committee Meeting).

o TA Execution Coordination Team Meeting.

o TA Execution Discipline Team Meetings (for HSE, Quality,

Operation, Maintenance Discipline, Project, etc.)

o TA Execution Control and Support Team (for EWR, Logistics, etc.)

 System or Equipment Hand-back.

Operation Activities during TA Execution

Operation activities during TA Execution is listed as follows (for detail

Internal
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Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

descriptions refer to Appendix V-11- Operations TAMG):

 Equipment First Entry

 Initial inspection to be conducted together with Inspection Team

and Technologist.

 Manway trays installation after completion of DOSH Inspection.

 Catalysts and Adsorbents Replacement which typically an operation-

controlled job.

 Joint Integrity monitoring.

 Equipment Box-Up and Refit monitoring prior to issuance of box-up

certificate and PASR-SU assessment.

 Tracking and managing PTW issuance and closure performance as

per TA PTW Plan.

Information  Primavera
Technology
 STEPS
Tools

Reference  Plant Policy, Work Processes and Procedures (Operation, HSE,

Maintenance, etc.)

 PETRONAS BFJI procedure and form.

 PTW procedure.

 GP work processes and procedures.

 EWR procedure and template.

 Daily TA Execution Progress Report template.

 Blinding Tracking template.

 OFWP.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Step 7.5.6 - Conduct Pre-Activity Safety Review (for Startup)

Description  This step describes the implementation of TA Pre-Activity Safety Review

for Plant Startup (PASR-SU) to evaluate risk and readiness to safely
startup the plant. PASR-SU “High” findings are required to be closed
before Safe Hand-back to Operation for plant startup process.

Inputs  Approved TIP.

 Approved TEP.

 TA Operation Planning Deliverables.

 TA Project Planning Deliverables.

 Integrated TA Execution Master Schedule and TA Systemization

Schedule.

 TA Mechanical Days activities completed.

 All WCS and JICS signed and completed (except for SIS and BLIS de-
blinding work).

 System or Equipment Hand-back completed and communicated.

 TA EWR Worklist Register and Tracking.

 PTW issuance and closure tracking.

Outputs  PASR-SU conducted.

 PASR-SU Report.

 PASR-SU “High” findings and mitigation plan closed.

 System or Equipment Hand-back completed and communicated.

Key
Responsibility Role Responsibility

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Site PASR Lead  Form TA PASR-SU Team

(Responsible for  Lead PASR-SU activity and facilitate the

initiation and session.
completion)
 Review PASR-SU report.

TA PASR  Coordinate PASR-SU activity.

Coordination
 Capture PASR-SU findings and develop
PASR-SD Report.

 Consolidate PASR-SU Findings and

Mitigation Plan into an Overall TA Risk
Register.
 Monitor, track and follow-up PASR-SU
findings closure status.

TA PASR Team  Conduct PASR-SU activity.

Site Operation Lead  Participate in PASR-SU activity.

 Endorse PASR-SU Report.

 Evaluate PASR-SU findings and approve to

proceed to the next step.

Plant Start Up /  Participate in PASR-SU activity.

Shutdown
 Review PASR-SU Report.
Coordination

Operation TA  Participate in PASR-SU activity.

Coordination
 Review PASR-SU Report.

 Coordinate and communicate Safe Hand-

back for each equipment or system
package from TA Execution Team to
Operation Team.

TA Execution Lead  Participate in PASR-SU activity.

 Review PASR-SU Report.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Planning Lead  Participate in PASR-SU activity.

 Review PASR-SU Report.

 Capture the official last Mechanical Days

date and time and communicate to all
stakeholders and workforce.

TA Execution  Participate in PASR-SU activity, if required.

Coordination Team

TA Operation Team  Participate in PASR-SU activity, if required.

TA HSE Team  Participate in PASR-SU activity, if required.

TA Quality Team  Participate in PASR-SU activity, if required.

 Monitor Safe Hand-back activities to ensure

compliance with TA Quality Plan.

TA Execution  Participate in PASR-SU activity, if required.

Discipline Team

TA Planning Team  Participate in PASR-SU activity, if required.

TA Project Planning  Participate in PASR-SU activity, if required.

and Coordination

TA Governance  Implement mitigation plan timely to close

Actionee PASR-SU “High’” findings before TA
Mechanical Days ends.

Service Provider  Support in implementing mitigation plan for

timely close PASR-SU “High’” findings
before TA Mechanical Days ends.

Site TA Committee  Participate in PASR-SU activity, if required.

 Monitor PASR-SU Findings and Mitigation

Plan Closure Progress and intervene as
necessary.

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WORK PROCESS
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Scheduling  Produce PASR-SD Findings and Mitigation

Plan Closure Status Report.
 Produce report on Safe Hand-back status.

Process  Timeliness of PASR-SU activity and report.

Measurement
 Timeliness of PASR-SU Risk Mitigation Plan action items closure.

 Timeliness of Safe Hand-back progress.

Guidance Pre-Activity Safety Review for Plant Startup (PASR-SU)

PASR-SU is a process to evaluate plant risks and readiness to perform

plant startup activities. PASR-SD findings (or punch-list) are categorized
as follow:

 “High” findings (i.e. punch-list “A”) - to be closed before plant

startup.

 “Medium” findings (i.e. punch-list “B”) - to be closed during Plant

Pre-Startup before Ready-For-Startup certification.

 “Low” findings (i.e. punch-list “C”) - to be closed during Post-TA

Execution.

It is recommended that the Site TA committee to evaluate pending

PASR-SU findings before proceeding to the next step.

Safe Hand-back

Safe Hand-back indicates the completion of all TA Mechanical Days

activities for each system package or equipment as specified in TA
Systemization to safely move to step “7.5.5 Pre-Startup and Startup
Activities”. Typically, it can be managed through closure of all PASR-
SU “High” findings and Return-To-Operation (RTO) certification from
Maintenance or TA to Operation.

Information  Primavera

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Technology
Tools
 STEPS

Reference  PASR-SU procedure and Assessment template.

 System Hand-back procedures and certificate template (i.e. RTO).

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Step 7.5.7 - Perform Pre-Startup and Startup Activities

Description This step describes plant pre-startup and startup activities required to
safely start up the plant for uninterrupted operation. The Pre-startup
activities ensures de-isolation of energy and process safety prior to
introduction of hydrocarbon to the plant.

The startup activities start when the plant feed is introduced to initiate
the processing and produce product. The “Last (On-Specs) On”
indicates the end of P2P duration and TA Execution period.

Inputs  Approved TEP.

 TA Operation Planning Deliverables.

 TA Project Planning Deliverables.

 Integrated TA Execution Master Schedule and TA Systemization

Schedule.

 TA Resource Loading Plan.

 TA Job Package activities and Mechanical Days activities (as defined

in Integrated TA Execution Master Schedule) completed.

 TA Execution plans and program (as defined in TEP) implemented.

 PASR-SU is conducted, report produced, and “High” findings closed.

 System or Equipment Hand-back completed and communicated.

Outputs  Plant Pre-Startup activities completed.

 New TA EWR Worklist implemented and completed.

 TA EWR Freeze Date communicated and implemented.

 PASR-SU “Medium” findings and mitigation plan closed

 Ready-For-Startup (RFSU) certified.

 De-isolation, de-energizing and LOTO removal completed.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

 Plant feed-in and Startup activities completed.

 Product produced and “Last (On-Specs) Product On” date and time
captured.

 Communication to all stakeholders on end of P2P duration and TA

Execution period.

 TA KPI tracked and reported.

 TA Execution Progress Report and Look-Ahead Schedule.

 TA EWR Worklist Register and Tracking.

 Manual Confirmation Order (MCO) list.

Key
Responsibility Role Responsibility

Site Operation Lead  Lead the overall Plant Pre-Startup and

Startup activities.
(Responsible for
initiation and  Chair TA Coordination Meeting during Plant
completion) Pre-Startup and Startup period.
 Initiate Pre-Startup activities.

 Initiate feed-in for Plant Startup.

 Capture and communicate “Last (On-Specs)

Product On” date and time.
 Evaluate PASR-SU findings and approve to
proceed to the next step.
 Evaluate Ready-For-Startup (RFSU)
checklist to ensure it is completed and
certified.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Scheduling  Produce overall Daily TA Execution Progress

and TA KPI Status Report.
 Monitor and analyze scheduling data and
actual Plant Pre-Startup and Startup
activities progress against the Integrated TA
Execution Master Schedule.
 Facilitate TA Execution Coordination Meeting

 Monitor daily actual resources loading

against plan and produce report.

 Develop TA Schedule KPI intervention plan

(i.e. Delay Recovery Plan), if required.

Plant Start Up /  Coordinate Plant Pre-Startup and Startup

Shutdown activities as per the Integrated TA Execution
Coordination Master Schedule.
 Manage LOTO for Safe Hand-back.

 Manage Master Blind list, blinding activities

and changes in blinding requirements.

 Coordinate the intervention plan and

resolves issues during Plan Shutting Down
period, if required.

TA Operation Team  Execute Plant Pre-Startup and Startup as

per the Integrated TA Execution Master
Schedule.

 Manage and supervise Service Provider’s

resources for Plant Pre-Startup and Startup
activities.
 Implement the intervention plan and
resolves issues during Plant Pre-Startup and
Startup period, if required.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Operation TA  Track completion of Plant Pre-Startup and

Coordination Startup activities for each equipment or
system package.

 Coordinate RFSU implementation.

 Screen the submitted TA EWR Worklist and

assign priority.
 Assign TA EWR Worklist with Process
System information.

TA Execution Lead  Form and lead Plant Startup and Startup

Support Team.
 Monitor and support the overall Plant Pre-
Startup and Startup activities.
 Review TA EWR Worklist.

 Declare and communicate the end P2P

duration and TA Execution period to all
stakeholders.

TA Execution  Coordinate support for the overall Plant Pre-

Coordination Team Startup and Startup activities (including
EWR).

Plant Start Up /  Troubleshoot and execute corrective

Shutdown Team maintenance during Plant Pre-Startup and
Startup activities.
 Manage and supervise Service Provider’s
resources to support the overall Plant Pre-
Startup and Startup activities.

TA Execution  Support the overall Plant Pre-Startup and

Discipline Team Startup activities as per assigned role.

 Support TA EWR Worklist planning and

manage the execution.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Service Provider  Execute EIS, BLIS and SIS de-blinding

work.
 Rectify any rework leaks during Plant Pre-
Startup and Startup activities.
 Provide support resources (manpower,
equipment, material, etc.) for the overall
Plant Pre-Startup and Startup activities.

 Plan and execute the approved TA EWR

Worklist.

TA Planning Lead  Monitor and support the overall Plant Pre-

Startup and Startup activities.

Emergent TA Work  Screen the submitted TA EWR Worklist for

Coordination completeness and accuracy of scope.

 Register, plan and track TA EWR Worklist.

 Declare and communicate TA EWR Worklist

Freeze Date.

TA Worklist  Evaluate emerging TA scope and submit TA

Originating EWR Worklist with detailed scope
definitions.

TA Worklist  Evaluate and approve TA EWR Worklist.

Approving

Site HSE Lead  Lead HSE-related Plant Startup activities.

TA HSE Planning and  Coordinate TA HSE programs, activities,

Coordination walkabouts and audits as per TA HSE Plan.

 Capture and report TA HSE KPI.

 Analyze HSE data and findings information.

 Produce TA HSE KPI intervention plan, if

required.

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA HSE Team  Implement TA HSE programs, activities,

walkabouts and audits as per TA HSE Plan.
 Monitor TA Execution activities and ensure
compliance to TA HSE Plan.

Site Quality Lead  Lead Quality-related Plant Startup activities.

TA Quality Planning  Coordinate TA Quality programs, activities,

and Coordination walkabouts and audits as per TA Quality
Plan.

 Capture and report TA Quality KPI.

 Analyze Quality data and findings

information.
 Capture any rework or leak during Plant
Pre-Startup and Startup activities.
 Conduct investigation on the rework or
leaks and produce TA Quality KPI
intervention plan, if required.

TA Quality Team  Coordinate JIT activities on Battery Limit

and System Isolation joints.
 Implement TA Quality programs, activities,
walkabouts and audits as per TA Quality
Plan.
 Monitor TA Execution activities and ensure
compliance to TA Quality Plan.

TA Project Planning  Coordinate and execute TA Project activities

and Coordination during Plant Pre-Startup and Startup period
as per Integrated TA Execution Master
Schedule.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA Logistics Planning  Coordinate equipment resources movement,

and Coordination inspection and site laydown.
 Manage TA Village and Temporary Facilities.

 Capture and monitor actual resources

(manpower and equipment) loading and
worker’s productivity data.
 Coordinate logistics support during Plant
Pre-Startup and Startup period including for
EWR.

TA Contract  Monitor contractors’ performance.

Controlling and
 Coordinate EWR services procurement and
Coordination
contractors’ workers’ mobilization.
 Support EWR services scope planning.

TA Budget Planning  Support in obtaining EWR approval.

and Cost Controlling
 Track and manage EWR cost versus budget.

 Track and report TA Cost KPI.

TA Material  Coordinate material issuance for work

Controlling and execution.
Coordination
 Support EWR material planning.

 Coordinate EWR materials procurement,

receipt, inspection and storage.

 Monitor and support in EWR material

tracking and expediting.

TA Material and  Procure and award EWR services.

Services
 Procure, track and expedite EWR materials
Procurement
until delivery.
 Manage Criticism of Material (COM).

TA Material Handling  Manage EWR materials delivery and receipt.

Internal
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Corporate Office

WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

TA PASR  Monitor, track and follow-up PASR-SU

Coordination findings closure status.

TA Governance  Implement mitigation plan timely to close

Actionee PASR-SU “Medium” findings before TA
Startup (RFSU).

Site TA Committee  Evaluate and endorse “Last (On Specs)

Product On” date and time.

 Monitor Plant Pre-Startup and Startup

progress and intervene as necessary.

 Provide directive, evaluate issues and

propose way forward.

Process  TA HSE KPI.

Measurement
 TA Quality KPI.

 TA Execution Schedule KPI.

 TA Cost KPI.

 % of TA EWR Worklist from the total TA Worklist.

 Timely EWR approval.

 Timeliness of PASR-SU Risk Management Plan action items closure.

Guidance Plant Pre-Startup Activities

Plant Pre-Startup activities are critical to ensure safe and timely plant
start-up. Typically, completion of activities is controlled and validated
through Ready-For-Startup (RFSU) checklist and certification.

The Pre-Startup activities include but not limited to the followings and
(for detail descriptions Appendix V-11 - Operations TAMG):

 Formation of Plant Startup Support Team to support Operation

Pre-Startup and Startup activities such as to rectify any leaking
joint, verify or re-calibrate the control system/instrumentation and
perform electrical switching. Some contractor’s manpower and

Internal
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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

equipment will remain at site for startup support.

 Continue TA Execution Coordination Meeting until the last (on specs)

product produced.

 Management, tracking and reporting of TA lagging and leading KPI:

o TA HSE KPI and manhours.

o TA Quality KPI.

o TA Schedule KPI.

o TA Cost KPI.

o Daily TA Execution Progress Report.

 EIS/SIS/BLIS and blinding management.

 Energy de-isolation (i.e. de-blinding, re-energize electrical power,

activation of radiation source, valve opening, etc.)

 Passivation of cooling water service equipment.

 Pressurizing and leak testing

 Leak testing and joints re-tightening

 O2 freeing, Inertization or Inerting.

 Flushing, purging and drying-out

 Insulation reinstatement

 Scaffolding removal

 Supply chain notification for utilities, feed supply and chemicals.

 Closure of PASR-SU “Medium” findings.

 Ready-For-Startup (RFSU) assessment and certification.

 Declaration of EWR Freeze Date.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

Ready-For-Startup (RFSU)

Ready-For-Startup (RFSU) indicates the completion of all plant pre-

startup activities to safely feed-in and startup the plant. Typically, it is
managed through closure of PASR-SU “Medium” findings and RFSU
checklist.

Plant Startup Activities

Plant Startup Activities is to set the installation in production mode to

produce product in accordance to specific startup procedures, which
normally contain following steps:

 Communicate to all personnel to startup the plant (after RSFU is

certified).

 Battery Limit Isolation System (BLIS)/System Isolation System

(SIS) de-blinding and energy de-isolation.

 Startup of machines and equipment.

 Taking in feed, processing and re-inventory of the installation. It is

a good HSE practice to have a “black-out” period during this time
to allow only authorized personnel inside the processing site.

 Resumption of production until plant capable of producing quality

product at design rate.

It is a good HSE practice to have a “black-out day” at a specified time

during Plant Startup period which allow only authorized personnel inside
the plant site to minimize exposure to the hazardous conditions.

Last (On-Specs) Product On

“Last (On-Specs) Product On” is date and time the final product
produce by the plant to indicate the end of P2P duration and TA
Execution period. The product shall be tested and confirmed meeting

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

the required specifications. The “Last (On-Specs) Product On” must be

clearly captured and communicated to all stakeholders and the
workforce involved.

At this point, all TA Execution strategies, plans, activities, work

processes and procedures as defined in TEP will be deactivated and
back to the normal plant operation i.e. EMWP as specified in TA
Transition Plan. Only some of TA Execution Organization Team
members remains to support Post-TA Execution activities.

Information  Primavera
Technology
Tools

Reference  Plant Policy, Work Processes and Procedures (Operation, HSE,

Maintenance, etc.)

 PASR-SU procedure and Assessment template.

 PETRONAS BFJI procedure and form.

 RFSU procedure and template.

 LOTO procedure.

 Blinding Management procedure and Tracking template.

 GP work processes and procedures.

 EWR procedure and template.

 Daily TA Execution Progress Report template.

 OFWP.

 EMWP.

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WPL1 Produce Product

WPL2 Maintain Facility Step
Description
WPL3 Plan and Execute Turnaround (PETA)
(Stage 5: Execute TA)

3. DOCUMENT HISTORY

Revision History

Revision No. Description of Amendments/Changes

0 Document created

Document Authorisation

Author: Kadrishah B Abdullah (CS_TACS/PCG) Date: 3 March 2020

Ashok Raman Kutty Date: 3 April 2020

Reviewer: (EVP_DOWNSTREAM/PETH); M Farid B
Ngah (Transformation/PCGB)

M Iskandar B Bakeri Date: 8 April 2020

Approver:
(EVP_DOWNSTREAM/PETH)

Internal
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