Shutdown & Turnaround Maintenance

Shutdown in Oil & Gas Industry

Shutdowns are planned and executed either as part of maintenance or to enhance operational efficiency or implement reengineering of processes for increased production and profitability. It is a war-like scenario where materials are drawn, workers are on the job performing repairs or maintenance, and equipment is replaced or serviced in a systematic manner.

Shutdowns are normally planned for an average of 30–45 days. When the ZERO day begins, all operations are closed, equipment is internally cleaned with steam, allowed to cool, and manholes are opened. Preliminary internal and external inspections of equipment are carried out. Based on these inspections, additional tasks are identified and added to the worklist. Welders perform repair work, the quality team evaluates the work using non-destructive testing, and once everything is checked and re-verified, the box-up activity starts. Safety teams ensure that no worker is left behind or alone in pressure vessels, columns, or tanks.

Since the country’s economy depends on Oil & Gas, shutdowns are well-planned and executed efficiently in the shortest possible time. This process is repeated annually, considering factors such as plant age and engineering process design—whether using old or new technology.

Engineers and technicians plan the jobs, which are then built and go through a commissioning program to validate all installations and production processes.

Post-Shutdown

The post-shutdown period involves carrying out necessary procedures to bring the refinery back to operational status.

Types of Shutdown

Item Shutdown

An item shutdown occurs when a specific equipment item is shut down manually because it is no longer required for duty or needs inspection or maintenance. It does not affect the entire process or plant. In some cases, two equipment items are connected in parallel to avoid a process shutdown.

Maintenance Shutdown

A maintenance shutdown involves shutting down, fully isolating, draining, and purging an equipment item to make it safe for maintenance work.

Unit Shutdown

A unit shutdown only affects a specific process unit in a plant, without shutting down the entire facility. Many units are connected to storage tanks, allowing downstream processes to continue operating using stored feed while another unit is offline.

Total Shutdown

A total shutdown involves shutting down an entire plant.

Emergency Shutdown

An emergency shutdown occurs in response to fire, major spills, or gas leaks. It shuts down the affected equipment as quickly as possible, followed by depressurizing and draining equipment and pipelines to leave them in the safest possible condition. Emergency shutdowns can cause additional wear and tear on machinery due to the reduced shutdown time.

An emergency shutdown is usually required for:

• Major spills and gas leaks.
• Serious oil fires.

Shutdown Warnings

If a shutdown affects upstream or downstream process units, advance warning must be given to the relevant personnel to allow them to prepare and respond to changing conditions. This includes suppliers of utilities and feedstocks, as well as downstream product receivers.

Countries JD Manpower Provides Shutdown Manpower For

UAE, Oman, Bahrain, Qatar, Kuwait, Saudi Arabia, CIS Countries, Russia, Africa, etc.

JD Manpower has a vast database of experienced candidates for all positions required to carry out the shutdown process smoothly and effectively.

Our candidates have experience working in extreme weather conditions, from -40 degrees in Russia to 50 degrees in the Gulf.