A shutdown, or turnaround, is when a refinery or plant stops producing its products for reasons such as inspections, repairs, or tests. The shutdown occurs for an extended period of time depending on the severity and/or importance of the desired objective. Shutdowns are important and expensive due to production loss, materials, labor, tools, and equipment. A shutdown is one of the biggest expenses of a plant or refinery’s annual maintenance budget. Because these temporary stoppages consist of detailed planning and skilled laborers, additional shutdown jobs are created to meet these demands.
Planner
A shutdown planner prepares itemized work scopes, estimates and guarantees a safe and efficiently operation. The planner conducts constructability reviews of all shutdown projects and provides accurate and punctual reports on safety, costs and schedules. A qualified planner should possess a high school diploma or GED; however, an undergraduate degree in engineering will enhance the chances of be accepted for a position as a planner. Additionally, at least five years or more of project planning experience in a refinery or petrochemical industry will enhance the probability of being hired as a shutdown planner.
Inspector
A shutdown inspector participates in the planning of a shutdown by approving the execution of the necessary repairs. An inspector develops procedures and practices for maintaining the equipment that needs to be fixed. Additional responsibilities include reviewing fabrication drawings and performing inspections to determine whether the fabrications conform to the proper specifications. Providing technical support to maintenance and production teams as well as directing the day-to-day occurrences of outside contracted inspectors are also responsibilities of a shutdown inspector. The qualifications of an inspector are at least a high school diploma or GED, though often undergraduate degrees are preferred. Certification in National Board of Boilers and Pressure Vessels (NBIC) is required as well as at least three years experience of inspecting fixed equipment and piping systems.
Mechanic
The mechanic provides the daily maintenance support, task execution and supervision to many factions within a plant or refinery A shutdown mechanic must be skilled in multiple crafts such as Fact System, drain and sewer system repairs, piping, tank repairs, steam leaks and trap repairs, filter and strainer cleaning, removal and cleaning of furnace burners as well as valve repacking and leak repairs. Additional knowledge operating a crane and forklift is required. Certifications in pipe welding, HAZWOPER (Hazardous waste operations and emergency response), and SCBA (Self containing breathing apparatus) are needed to work as a shutdown mechanic.
Scaffold Builders
Scaffold builders are essential to a shutdown because access to specific areas is crucial. Many areas within a plant or refinery that need to be cleaned, repaired or inspected are located several feet off the ground or deep inside reactors. The temporary structures consist of tubes, couples and boards that must be built to accommodate workers, tools and machines. A scaffold builder must have the OSHA scaffold certification and training, which teaches the regulations, rules and requirements requested by the Occupational Safety and Health Administration. Additionally, scaffold builders must be familiar with the requirements for training employees on the use and construction of the structure.
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