07 Jul 2015
A Complete Information On Planning Shut Maintenance Work
A Complete Information On Planning Shut Maintenance Work

The temporary shutdown of a manufacturing plant for improvements in equipment and processes must be made with the utmost planning and coordination to achieve the desired aims in the most timely, safest, and cost-efficient manner.

Effective shut planning and execution of shutdowns and turnarounds is essential to maintain product levels and reduce the loss of revenue, particularly if improper maintenance leads to an unplanned shutdown.

The effects of unplanned shutdowns or changes to schedules can have a profound impact not only on the company operating the facility but also on the wider economy.

Therefore, in the planning phase, the facility’s internal team, the prime contractor hired for the project, and the various engineering disciplines, both internal and external, determine the scope of work to be accomplished, the pre-shutdown activities that are required, and general logistics. With this preliminary game plan in place, they define the human resources that will be required for the project.

At this point, the key players negotiate the schedule. The prime contractor will want adequate time to carry out the project without unduly taxing the resources and causing critical tasks to be rushed. The owner will advocate for condensing the schedule to minimize loss of production time. In the end, the compromise usually involves working around the clock, through weekends and holidays, to satisfy both points of view.

The planning phase can take anywhere from one to three months for all resources to be properly vetted and the scope of work defined.
Shut Maintenance projects require personnel experienced in shutdown procedures to conduct a number of activities, including:

  • Optimising timing and developing a schedule for the shut
  • Determining the critical path for the activities
  • Determining the labour, equipment and consumables required for the pre-shutdown preparation and during the shut
  • Identifying and procuring critical spares required during the shut
  • Finalising work scopes for engagement of contractors
  • Determining planned maintenance activities for each engineering discipline
  • Developing final inspection criteria

Support in the Planning & Coordination of a Shutdown is Crucial And Ensures:

  • All necessary activities are identified, planned and carried out .
  • Costs are controlled through sound planning and scheduling techniques.
  • Materials and services are available at the right place and the right time to maximise the success of the shutdown.
  • Risks are identified and addressed during the planning phase of the shutdown.
  • The shutdown duration is minimised in order to reduce the impact on business performance.

Shut Maintenance including tests, measurements, adjustments, and parts replacement, is performed specifically to prevent faults from occurring.

The primary goal of maintenance is to avoid or mitigate the consequences of the failure of equipment. This may be by preventing the failure before it actually occurs which Planned Maintenance and Condition Based Maintenance help to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail. In addition, workers can record equipment deterioration so they know to replace or repair worn parts before they cause a system failure. The ideal preventive maintenance program would prevent all equipment failure before it occurs.

Organising a mine shutdown in the remote Pilbara region can be a challenge.


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Posted in Shut Maintenance