Maintenance
3 . Prepare for the unexpected
No matter how well planned a turnaround is , there will be variables and contingencies that will come along unexpectedly . Operators who think about potential scenarios ahead of time may aid overall project efficiency . For example , because of the large and complex nature of the fluid systems throughout chemical plants and refineries , it is practically impossible to know exactly which , and how many , specific components will be needed throughout the turnaround . For that reason , it is beneficial to stock up on a variety of hoses , valves , and adapters prior to the start of the project . Having basic components already on hand can be a significant time saver versus having to order additional parts once installation is already underway . Of course , no operator wants to be stuck with unused inventory . For that reason , it can be beneficial to seek out terms with suppliers allowing you to stock temporary or consignment inventory so that the right parts are always available . Under these conditions , you will only need to pay for the parts used during the project .
4 . Ensure the availability of local support
When unexpected challenges do arise , it is important to be able to access system parts in a timely manner . That is why working with vendors who can offer localised support near the plant is important . Having adequate coordination with vendors who can handle any unforeseen parts sourcing quickly in the event of a problem will help the turnaround proceed without significant interruptions .
5 . Keep a close eye on installation of critical parts
In the most ambitious of turnarounds , the number of technicians working at any given time can be overwhelming . Hundreds of workers from different firms and disciplines may be on-site at the same time , and the level of installation expertise may vary . When it comes to doing an effective plant turnaround , this inconsistency can cause significant problems for the plant owners . One way to standardise the installation skill levels across all the involved vendors is to specify which training and certifications are necessary in the initial request for proposal ( Figure 2 ). If the vendors understand what will be required from a training and certification standpoint , they will provide workers who have certain baseline knowledge and are familiar with proper installation best practices .
6 . Seek out prefabricated assemblies
Another way to ensure complex fluid systems are installed properly is to use prefabricated , preassembled , and pretested components . When components are standardised , contractors will be able to install critical systems more efficiently , saving time and money in the long run . Additionally , using prefabricated assemblies may also address any discrepancies in installation experience between different vendors and contractors . As discussed , grab sampling panels are an excellent example of how prefabricated systems can save time and money , while allowing
Figure 2 . Standardise installation skill levels across all vendors to determine which training is needed in the initial proposal request . Images © 2022 Swagelok Company
Figure 3 . Tight , up-to-date specifications can make turnarounds more effective . Images © 2022 Swagelok Company
for safe , efficient sample capture specific to the plant . Elsewhere , mechanical seal support systems improve mechanical seal longevity . Finally , analytical subsystems , including fast loops , field stations , calibration and switching modules , sample probes , and fluid distribution headers offer additional efficiencies and consistencies to plant operations while simplifying design footprints .
7 . Maintain tight quality control
It is in an operator ’ s best interest to maintain strict control of the quality and consistency of parts being installed . Specifications that allow too much flexibility may lead some contractors to source less expensive and lower-quality components . Inconsistent quality parts across different systems can lead to inconsistent performance , premature maintenance needs , or downtime later on . Keeping a tight , up-to-date specification that allows only for the use of high-quality components in critical fluid systems is one more way to make turnarounds effective ( Figure 3 ). In addition , the more an operator can avoid intermixing parts from different suppliers , the easier it will be to maintain systems consistently in the future . These seven steps will help chemical plant or refinery operators achieve faster , more efficient turnarounds while improving the long-term reliability and performance of fluid systems . Partnering with the right supplier — one that can offer local component , design , and installation advice — will help provide the necessary guidance to make plant turnarounds go as smoothly as possible .
32 Valve World November 2022 www . valve-world . net