Key Principles for

Successful Shutdown
Maintenance Planning
R. D. (Doc) Palmer, PE, MBA, CMRP
Maintenance Planning and Scheduling Handbook
Richard Palmer and Associates

2007 Eventure Events. All rights reserved.

 Key Principles for Successful Shutdown
Maintenance Planning

Introduction to Effective Planning and

Scheduling
Benefits of planning and scheduling
Additional requirements beyond
Principles of planning
Principles of scheduling
Considering reactive work

Doc Palmer
 Key Principles for Successful Shutdown
Maintenance Planning

Moving from Weekly Maintenance

to Outage Maintenance
Accuracy of task estimates
Cycle of improvement, the outage report
Controlling scope
Short notice outages versus planned
turnarounds

Doc Palmer
 Key Principles for Successful Shutdown
Maintenance Planning

Organizing and Executing Shutdowns

Outage organizing
CMMS benefits and cautions
Pre-outage, during-outage,
and post-outage tasks
Defining outage success

Doc Palmer
 Introduction to Effective
Planning and Scheduling

2007 Eventure Events. All rights reserved.

 Benefits of
planning and scheduling

Consider P&S for non-outage maintenance

Its not about parts and tools
Its not about using a computer
It is about getting more work done
Why do we plan?
To increase productivity right answer
To provide job packages wrong answer

Doc Palmer
 Benefits of
planning and scheduling

Tradesperson wrench time commonly

thought to be 80% or so
Actual industry avg between 25% & 35%
Improving from 35% up to 55% wrench time is a
57% improvement (55/35)
30 mechanics X 1.57 = 47 mechanics (17 free)
(Improving from 25% up to 50% would double
workforce; 30 free mechanics)

Doc Palmer
 Benefits of
planning and scheduling

1 planner can plan for 20 to 30 tradespersons

Value of 1 planner = 17 tradespersons
Industry rule of thumb: $1 invested in proper
maintenance = $10 plant profit
Value of 1 planner=170 tradespersons?
There is money involved

Doc Palmer
 Additional requirements beyond
planning and scheduling

Workforce focus on quality

Leadership/communication/teamwork
Storeroom/tools/shops
PM/PdM/project work
Skilled workforce including supervision
Proper work processes

Doc Palmer
 Essence of
planning and scheduling

Planning supports improving individual jobs

repeated over time: a cycle of improvement for
each job
Planning supports advance scheduling by
identifying craft skills and labor hours
Scheduling sets goals to assign a sufficient
amount of work

Doc Palmer
 Six principles of PLANNING

1. Planners separate from crews

2. Focus on future work, not chasing parts on
current work
3. History files at component level
4. Use planner skill to estimate labor hours
5. Plans recognize skill of tradespersons
6. Recognition of wrench time issue

Doc Palmer
 Six principles of SCHEDULING

1. Need job plans with craft skills and labor hours

2. Credible priority system in use
3. Forecast crew labor availability for week
4. Schedule 100% available labor hours
5. (Crew leader handles daily schedule)
6. Measure weekly schedule success

Doc Palmer
 Must consider REACTIVE work

Its okay to break the schedule

Reactive work
Dont make crews wait
Plan differently: Peek at job and history file; plan
scope, skills, and hours
Emergency work (Unit is down)
Its okay to chase parts

Doc Palmer
 Success in routine maintenance
CLOSED WORK ORDERS PER MONTH
Mechanical Maintenance
300

Started Weekly Scheduling

250
Changed Planning Approach
200

Ran Out of Backlog

150

100

50

0
O N D J94 F M A M J J A S
FY93/94

Doc Palmer
 Moving from
Weekly Maintenance to
Outage Maintenance

2007 Eventure Events. All rights reserved.

 Accuracy of task estimates

+/- 100% for individual tasks

+/- 5% to 10% for aggregates of tasks
Application:
We can use estimates to control work
Dont get excited about a single task
Look for overall progress in areas

Doc Palmer
 Cycle of improvement

We repeat maintenance over time

We repeat outages over time
Application:
Improve time estimates and quality of individual jobs
and outages over time
Must have files and good record keeping
Its okay if this outage is not perfect

Doc Palmer
 Cycle of improvement: Files

Good library
Outage notebook and outage checklist
Evolve shutdown and startup checklists
Hold critique after outage including managers
and tradespersons
Each project manager within outage must write a
report following project closeout outline

Doc Palmer
 Cycle of improvement: Files

Project closeout reports

Title and description
Work order #
Project mgr
Start date and substantial completion date
Punch list completion date
Contractor and subcontractor
Purchase order # and issue date

Doc Palmer
 Cycle of improvement: Files

Project closeout reports (continued)

Final project cost
Warranty end date
4 copies O&M manuals delivered to maintenance
planning dept including
Copy of approved submittals (cut sheets)
Table of contents
Lubrication and PM recommendations
Spare parts list
Correct size 3 ring binder

Doc Palmer
 Cycle of improvement: Files

Project closeout reports (continued)

Inventory
Request to planning dept to add new
Request to planning dept to delete obsolete
Drawings
New drawings hard copy and electronic with equip #s,
meaningful titles, and as-built
Revisions to existing drawings clearly marked for
draftsman to understand

Doc Palmer
 Cycle of improvement: Files

Project closeout reports (continued)

CMMS (Computer Maint Mgt Syst)
Obtained new equipment #s
Submitted list of obsolete #s
Training
Conducted for Maint and Opns as necessary
Submitted any operational procedure changes to Opns
List of any special tools used

Doc Palmer
 Controlling scope

Why? To limit scope creep

Need cut off dates for adding scope
Need process for adding scope

Doc Palmer
 Controlling scope

Know why we are doing this outage

To make a successful investment right
Tradition or To get it done wrong
Is outage needed?
Equipment problems including wear
Dont just fix symptoms every outage, solve root
causes
New technology

Doc Palmer
 Controlling scope

Have a strategy for outages overall

Plan knowing strategy
Large outage every 5 years or
Component outage every 2-3 years (HP/IP, LP)
Do as much as possible outside the outage
Yet consider ease of clearing equipment for work
Publish 1 year and 10 year outage plans
Update monthly

Doc Palmer
 Controlling scope: Outage plans
One Year Outage Plan for June 2006 (by season)
Changes
None since last month

New outages
None since last month

Fall 2006 outages

NS 2 TURBINE UPRATE (10/25/06 12/19/06)
NS CT 6 MAJOR OUTAGE/TURBINE WHEEL REPLACEMENT (09/15/06 -12/15/06)

Spring 2007 outages

NS CT 5 HOT GAS PASS INSPECTION/TURBINE WHEEL REPLACEMENT (ROW 1-3)
(02/17/07 - 05/11/07)
PP 1 INSTALL NOx TIE INS BLR/BFP TURBINE VALVES (02/24/07 04/02/07)
NS 1 INSPECTION/REPAIRS (4 WEEKS SPRING 2007)
KS CT 7 COMBUSTION INSPECTION (10 DAYS SPRING 2007)
NS 3 GENERATOR REWIND (11 WEEKS BEGINNING IN MARCH 2007)

Doc Palmer
 Controlling scope: Outage plans
Ten Year Outage Plan for June 2006 (by unit)
Changes
The fall 2008 NS2 outage has been cancelled
The spring 2010 KS CT3 outage has been lengthened from 7 to 8 weeks

New outages
None since last month

Outages
PP1 INSTALL NOx TIE INS BLR/BFP TURBINE VALVES (02/24/07 04/02/07)
BOILER/FGD (02/25/08 04/03/08)

NS 1 INSPECTION/REPAIRS (4 WEEKS SPRING 2007)

INSPECTION/REPAIRS (4 WEEKS SPRING 2008)
INSPECTION/REPAIRS (4 WEEKS SPRING 2009)

NS 3 GENERATOR REWIND (11 WEEKS BEGINNING IN MARCH 2007)

MAJOR OUTAGE (4 WEEKS FALL 2010)
Doc Palmer MAJOR OUTAGE (4 WEEKS FALL 2015)
 Controlling scope
Start 1 to 2 years before the outage
Review previous outage reports for what
you might expect this time
PdM (predictive maint) group must share info
Conduct meetings (inclg tradespersons) and
make discovery lists
Republish lists with increasing freq as start
date approaches
Communicate with everyone, sideways
+ up and down + inside and outside
Doc Palmer
 Controlling scope

A lot of discovery work added too late will

wreck an outage
Prevent: Reduce with PdM; Anticipate from history
Adding discovery work
Watch for impact items; items that affect funding,
resources, schedule
Have review process; who will pay?
Dont sweat little stuff

Doc Palmer
 Controlling scope

Have component outages

Easier to defer discovered work
Less financial burden, spread out costs
$3-5 million every 1-2 years instead of $15-20 million
every 5 years
Allows focusing resources
Less overwhelming

Doc Palmer
 Controlling scope
Avoid routine rebuilds which introduce infant
mortality

Failure A
rate
X
versus B
time

Rebuilding equipment in Figure A at Point X

may result in Figure C instead of Figure B
Doc Palmer
 Controlling scope

Routine PM (preventive maintenance)

Issued well in advance into backlog
Planner review for material and contractor needs
State (During Outage) in title as well as use outage
codes
Prioritize as Must, Prefer, If time

Doc Palmer
 Controlling scope

Learn to say No
Shutdown manager needs authority
Scope freeze time
Need organizational discipline (leadership)

Doc Palmer
 Controlling scope

Use a work breakdown structure

Defines scope and deliverables
Gives visibility

Shutdown

Condenser Turbine Actuator Project 4 Project 5

work uprate rebuilds

Dissemble Modify Blades Reassemble Backlog Backlog Backlog

Inspect Repair
work Mech work Elec work I&C

Doc Palmer
 Short notice outages versus
planned turnarounds

Identify work as requiring an outage

Plan outage work expediently
Pay close attention to parts needed
Take advantage & do as much work as possible
outside planned turnarounds
Be able to find outage work that can be done
within constraints of the SNO

Doc Palmer
 Organizing and Executing
Shutdowns

2007 Eventure Events. All rights reserved.

 Organizing for outages

Shutdown manager
Comprehend technology of the outage
Good record keeping
Awareness; manage by wandering around
Full time for large outages 6 months to a
year before start
Agreement with sponsor, authority: what, when, who

Doc Palmer
 Organizing for outages

Outage organization elements

Shutdown manager

Opns for clearances/permits

Accounting Safety
Scheduling Project mgrs Maint crews Engrg
Environmental
backlog work
Purchasing PdM Legal
Stores QA
Tools Contractors Maint crews
project work

Doc Palmer
 Organizing for outages

Need defined and known processes

Budgeting, trend program
Stores (inventory), tools
Purchasing regarding services, labor, material,
receiving, laydown
Insulation, scaffolding
Safety, certification, reporting, work permits,
clearances, lockout-tagout, confined space
Configuration mgt, design change notification, project
closeouts, as-builts

Doc Palmer
 Organizing for outages

Know that you have the resources to do the

outage!
Funds, Time (before and during)
Crafts, welders, engineers, project mgrs, etc.
Tools, cranes, fork lifts, etc.
Vendors, contractors
Avoid dumb overtime that exceeds fatigue limit

Doc Palmer
 Organizing for outages

Budgeting
Need a budget
May need a multi-year budget through different fiscal
years
Funding timing
Anticipate some unknowns

Doc Palmer
 Organizing for outages

Cost control
Need tool fairly accurate and timely
May have to stop some work or raise budget
Understand cost reports when controlling project:
committed, encumbered, expensed
Trend program

Doc Palmer
 Organizing for outages

Contractors
Understand any need to contract
Contractors need to be familiar with the way you do
business
Contract for known circumstances
Settle on unknown circumstances encountered
Budget for anticipated circumstances

Doc Palmer
 Computerized maintenance
Benefits
Standardize work processes
Find work orders and parts
Identify any outage work with Unit Condition field
code (e.g. 2 = requires unit outage)
Identify all work orders for this outage with
Outage ID field code (e.g. N03 Spring Outage 2007)
Assign work order #s to all projects;
add assigned lead name to each
Information for metrics and reports
Helps history; see past work orders
Doc Palmer
 Computerized maintenance

Cautions
If you dont know how to do it without a
computer, a computer will not help
Faulty processes / distraction
Improper costing
System reliability and speed
User friendliness
Cost of system

Doc Palmer
 Executing the shutdown
Schedules

Pre-outage schedule
Tracking to see all
During-outage schedule
Detailed or non-detailed (milestones or flags) okay
After-outage tasks

Doc Palmer
 Executing the shutdown
Pre-Outage

Start planning this turnaround after the last one

on this unit
Budget, prepare to order long lead time items
Investigate lead times, could be 18 months
Research vendors and availability, consider
other companies and spares

Doc Palmer
 Executing the shutdown
Pre-Outage
Set aside (kit) parts to insure on hand
Make sure special tools are ready
Contractors need to mobilize; space,
laydown, trailers
Be ready to clear equipment for work in
sensible order
Communicate with everyone, sideways + up
and down + inside and outside

Doc Palmer
 Executing the shutdown
Pre-Outage

Start outage
on time!
Need organizational discipline

Doc Palmer
 Executing the shutdown
During-Outage

Can manage to milestones instead of a

weekly schedule
Regular, short project meetings
Persons dont resent going to; have
opportunity to share
Note milestones (or flags) or collect %
complete per work breakdown structure as
appropriate.

Doc Palmer
 Executing the shutdown
During-Outage

Beware the 90% done syndrome

Beware Parkinsons Law (work expands to
fill available time)
Finish outage backlog and do other
maintenance work if time left
Finish outage early if appropriate;
but dont kill self

Doc Palmer
 Executing the shutdown
During-Outage

Crew supervisors do daily or shift schedules

and coordinate work
Outage planners can chase parts
(Unit is down). May need an expediter
Communicate with everyone, sideways +
up and down + inside and outside

Doc Palmer
 Executing the shutdown
During-Outage

Outage not over until unit is reliably operating

Include start up time as part of the outage
schedule
Especially with new equipment

Doc Palmer
 Executing the shutdown
After-Outage

Closeouts
Critique, lessons learned
Rate the outage, score numbers
e.g. include planned vs unplanned hours
and forced outages within 30 days
Keep in history

Doc Palmer
 Success in outages

Outage objective met; completed scope of work

intended; was good investment
Completed on schedule
Completed on budget
Good safety, environmental, legal performance
Not overwhelmed by surprises
Good startup; reliable unit performance

Doc Palmer
 Success in outages

This outage was better than the last

Work identified for next outage
Other information gathered to help next outage
and finally
Outage personnel are still friends

Doc Palmer
 Question time

Doc Palmer
 Doc Palmer
Maintenance Planning and Scheduling Handbook
www.palmerplanning.com
[email protected]

2007 Eventure Events. All rights reserved.