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What are the phases of a turnaround maintenance procedure?

What are the phases of a turnaround maintenance procedure?

In the field of maintenance, we have a turnaround event in which we remove a few assets temporarily so that we can perform maintenance on them, like this the regular tasks are not disturbed. The turnaround procedures are different in every organization keeping in mind various assets they use, but the main phases remain same which are as follows:

  • Scoping
  • Preparation
  • Execution
  • Start-up
  • Evaluation

Step 1: Definition/Scoping

Turnaround happens when a asset is taken out temporarily that brings us to a situation when we will experience a downtime. However, we cannot stop the operations for a longer period. Because if this will happen it will lead to heavy losses in production. This brings us to a point where we should know that the turnaround should be well planned, it is must to insure that we are not wasting the lost time.  

In first step a list is being created in which we will list what needs to be done on an asset, what kind of maintenance. There are chances of performing different kinds of activities like performance tests, repairs, standby etc.  

The output that we will receive after performing this first step is that we will have a complete list of activities to perform on each asset. A CMMS is the best tool that we can use to keep a track of the turnaround work list that we will create.  

Step 2: Preparation

Now that the work list is ready and that we know what we need to do on every asset next step is to identify the resources that we will need to complete all the tasks in scheduled time. Preparation includes not just getting all the resources but also checking if the employees have proper knowledge of the training that they require. To perform the tasks mentioned in that list. We would also be considering the matter of staff requirements. Management team decides whom to assign the tasks to.  

This step also include keeping an eye on safety requirements that one needs to check on. Some maintenance activities are required to reduce the risk and avoid the unexpected incidents.  

Step 3: Execution:

Execution phase begins with stopping the equipment completely. The tasks that we will encounter in this phase would be inspecting the asset, taking corrective measures, testing the equipment.  

Tasks are updated, what is done and what is not. The progress can be tracked using the CMMS software, easily.  

Step 4: Start-up

The next step is the start-up stage. This step is just an extension of the previous step. And then the transition of bringing the asset back to normal. After all the tasks have been performed that were supposed to be performed. It is an operational stage but throughout the procedure the assets are being closely monitored. Once the conditions are being met, we can ramp the whole process. Ramp up is the gradual process of bringing the assets back to normal work. This phase reduces the risk of incidents in the facility.  

Step 5: Evaluation

Evaluation step is all about bringing in what all is done. This is the evaluation of all the cost incurred from the turnaround process, it is all about looking back and analysing the work orders and purchase orders. Any thing that is left over can be credited back and looked closely up to.  

Any resource that we did not use can be kept aside for use in future. An audit is conducted in this stage in which we evaluate the condition of each asset.  The final data and observations provide us information on plant’s safety, efficiency, performance metrics, and overall performance.