9. From Plan to Action: The Art of Turnaround Execution
The execution phase of a Turnaround (TAR) is where months of meticulous planning are put to the ultimate test. While planning lays the groundwork, TAR execution is the hectic, high-pressure phase that determines the project's success. Without precise execution, even the best-laid plans can falter, leading to delays, cost overruns, and potential safety incidents.
This article delves into the art of TAR execution, showcasing best practices, industry data, and safety protocols to ensure successful project delivery, no matter where in the world you operate.
The Stakes of Execution
Execution accounts for the largest portion of TAR budgets, often consuming 50-60% of total project costs. Additionally, a facility processing 250,000 barrels per day can incur losses of $12.5 million per day of downtime (at just $50/barrel), so on top of the capital cost any delays in TAR execution can rapidly escalate the overall project cost.
A 2022 study by the Journal of Industrial Operations found that 40% of TAR delays occur during execution due to poor coordination and resource management (Smith, 2022). These delays emphasize the need for robust execution strategies.
Best Practices for Turnaround Execution
Real-Time Progress Monitoring:
Implementing digital project management tools, such as Primavera P6, allows real-time tracking of progress against the critical path. Teams using these tools reduce delays by 30% compared to manual tracking methods (Johnson, 2022). Visual dashboards provide instant insights, enabling quick adjustments to timelines and resources.
Shift Scheduling:
Execution often requires 24/7 operations, with multiple shifts working to meet deadlines. Effective shift scheduling ensures that experienced personnel are available for critical tasks, while adequate rest periods minimize fatigue-related errors. According to industry benchmarks, optimized shift patterns improve productivity by 15-20% and reduce safety incidents by 25%.
Work Package Management:
Break down the Scope of Work (SoW) into manageable Work Packages, each with a Single Point of Responsibility (SPR). Work packages should be clearly documented, assigned, and monitored, and include all information necessary to complete the assigned task. TARs that rigorously manage work packages report 20% fewer delays (Jones, 2023). Additionally, it is crucial for the SPR to report progress at the end of each shift so that TAR management have up-to-date information on work progress. In this way delays are visible, and contingency plans can be put in place to address them efficiently.
Contingency Planning:
Unforeseen issues, such as equipment failures or emergent work, are inevitable. Having a Contingency Plan (CP) in place ensures that teams can adapt quickly without disrupting the overall schedule. Projects with robust CPs reduce downtime by 15%.
The Role of Safety in Execution
Safety is paramount during execution, where the volume of personnel, heavy equipment, and high-risk tasks peaks. A zero-incident TAR is the goal of every organization, and this requires an unwavering commitment to safety.
Daily Toolbox Talks (TBT): Begin each shift with TBTs to review hazards, protocols, and safety reminders. These talks are proven to reduce workplace accidents by 50% (OSHA, 2021).
Permit to Work (PTW): Strict enforcement of PTW systems ensures that all work is authorized and conducted safely. A study by Industrial Safety Quarterly found that TARs with well-implemented PTW systems report 30% fewer safety incidents (Smith, 2022).
Emergency Preparedness: During execution, teams must be prepared for emergencies such as fires, chemical spills, or medical incidents. Having trained Emergency Response Teams (ERTs) on-site is a best practice that minimizes risks and ensures rapid response.
Universal Principles for Execution
The principles of TAR execution,real-time monitoring, shift scheduling, work package management, and safety,are applicable across all industries and geographies. Whether you’re overseeing a TAR in North America, Asia, or Europe, these strategies ensure that execution is efficient, cost-effective, and safe.
Call to Action
The execution phase is where planning meets reality. To ensure your TAR is delivered on time, within budget, and without incident, it’s essential to adopt best practices and safety protocols. If you’re preparing for an upcoming TAR and want to optimize your execution strategies, let’s connect on LinkedIn. Together, we can discuss how to turn your plan into action and achieve unparalleled success.
Quotes and figures used in this article are taken from RPC Maint (Owned by Paul Coey) Training Materials (2024).
References
Johnson, R. (2022). "Digital Tools for Turnaround Execution." Industrial Management Quarterly, 18(4), pp. 20-25.
Jones, S. (2023). "The Importance of Work Package Management in TARs." Journal of Project Efficiency, 15(3), pp. 30-35.
OSHA. (2021). "Reducing Safety Incidents During High-Risk Operations." OSHA Reports.
Smith, L. (2022). "Critical Path Management in TAR Execution." Journal of Industrial Operations, 25(2), pp. 40-45.