WBS for Shutdown

Example (roughly) from PMI/WBS guide;

Root - T/A (shutdown)
.Pre T/A
.Shutdown
.Main T/A
..Airtest (or system) 1
..Airtest (or system) 2
...Civil
...Ovens
...Exchangers
...Vessels
...Reactors
....Reactor1
.....Work order 1
......Work order activity 1
....Reactor2
....Reactor3
...Valves
....Relief (safety) valves
....Control Valves
...Piping
...E&I
..Airtest (or system) 2
.Comissioning
.Post T/A
.PM/Engineering

Looked at another way

Root- T/A
Level 1 - Phases
Level 2 - System (airtest, product train etc)
Level 3 - Scope type / equipment type
Level 4 - Equipment Tag Number
Level 5 - Scope item Number
Level 6 - Activity
..
Level 7 - Calculation line

We have a team calculate manhours at calculation line level following a standard set of rules (xxx MH to remove yyy lb flanged block valve etc * zzz% factor for working at height etc). This is compiled per scope item and is an involved process, taking roughly 8-12% of the calculated hours to produce properly. This data is imported into the scheduling software (in our case P3.1) and integrated with an overall phasing plan. Shutdown and startup activities under the purview of production staff is scheduled separately and integrated in parallel.

Phasing schemes will vary from refinery to refinery. We use;

Phase 0 -Preturnaround works
Scaffolding, labelling valves, set up cleaning areas, some E&I etc

Phase 1 - Shutdown unit

Completes with Blinding Batterylimits and flare

Phase 2 - Secure equipment

Typically blind, steam, open, first cleaning and O2 test

Phase 3 - Execution

Full cleaning, dissassembly, inspection, repair, reassembly, testing, Hand over back production

Phase 4 - Deblind

Deblind equipment and airtest by system, Punch

Phase 5 - Startup

Phase 6 - Post T/A works

Is it a small stop (for a cat change etc?) If so than 4 weeks is probably sufficient (although you’re behind the curve being on your first one....) Best source of info will be the people who were on the unit the last time it was shut down, they will know the subtleties of the procedures that aren’t covered in the manuals. The manuals rarely make sense anyway :P

If you don’t have the time to schedule it properly (resource levelled etc), at least make sure you have a good reporting system. The main task of the scheduler during execution, I find, is to keep a view on what is needed to complete each airtest and ride the critical path out.

OTOH, if the stop is big enough to require resource levelling and you’ve only 4 weeks till shutdown then hold on to your hat, you’re in for a wild ride!

James,

You couldn’t of explained it better!

However, do you incorporate level 7 into p3 or use a another database, then summarise it as level 6. eg, scaffold, inspect, repair etc..hrs to change/inspect valve say.

Just thought, i have the option of p6 which has a steps function, could i use this for level 7? or would it be too much?

Cheers mate!

For us, Level 7 is prepared in a separate database then uploaded to P3.

I don’t know what P6 capabilities are wrt work "preparation" as they term it here but P3.1 certainly doesn’t have enough depth.

If you don’t have a preparation scheme in place I would be shocked if you could get one up and running in 4 weeks. We’ve just changed over to a new preparation package and it’s taken an order of months to implement. However, we are preparing TAs of 250,000 MH and up. We have another team that looks after smaller stops and cat changes. They use a different package but I think that for very restricted scopes (say <100 Work orders) you might cobble something together in access / excel quickly that would allow you to break down the work and calculate teh hours for upload to P3 ... or even do it directly in P3.

Glad to be of help, I was dumped into it a bit when I started and so happy to lend a hand where I can

Email me, I will send you the sample shutdown schedule for Gas Processing Plant.

Cheers,

Chintoo

Hi Mujahid,

Thank you very much for the copies you’ve sent.

Best regards,
Gerry

Dear Mujahid,
Can i have the copy of the same at imran.arshad1@gmail.com.

Thanks in advance.

Regards,
Imran

Hi Mujahid,

Can i also have a copy of the same at grridulme@yahoo.com


Thanks in advance

Regards,
George

me too. olyke@yahoo.com
thanks

Hi Mujahid ,

If you dont mind can i have a copy e-mailed to vinodraturi123@gmail.com.

Its great to be in this forum , where planners are always ready to lend a helping hand.

Thanks,

with regards,

Hi Mujahid,

Please send it to my email add also ---- diony.cornico@gmail.com.

It will help me a lot...


Thank you very much and best regards,

DIONY

Dear All,

If you want this sample shutdown schedule which Chintoo / Mujahid offered over 3 years ago, send him a private message (the envelope icon next to his name) with your email address.

 

I am locking this thread as it has become another begging letter.