To Achieve Best-in-Class STOs, Start with Best-in-Class Operations, Maintenance, and Inspection Organizations


Shutdowns, Turnarounds, and Outages (STOs) are among the most complex and resource-intensive events in plant operations. As the saying goes, “A good plan is a success half-done, whereas a bad plan is a possible failure in progress.” A robust STO plan should consider all scenarios, integrating perspectives from every operational aspect. Success not only depends on the turnaround group, but on a coordinated effort across the plant’s people, tools, and processes. Let’s explore how best-in-class organizations across reliability, operations, and maintenance pave the way for STO excellence.

Best-in-Class Reliability and Inspection Groups

Reliability and inspection teams are pivotal to STO readiness and post-event performance. Their contributions extend beyond planning to ensure long-term reliability and operational integrity. Key areas of focus include:

  • Risk-Based Inspection (RBI) for Scope Selection and Management: Leveraging RBI methodologies enables reliability teams to prioritize critical assets and validate scopes effectively. By focusing on high-risk areas, teams can optimize resources and reduce unnecessary work. 

  • Data Integrity: Accurate, accessible historical data is essential for informed decision-making. High-quality records of equipment performance and inspection history allow teams to identify patterns, validate scopes, and make data-driven decisions.

  • Data Collection Tools: Digital reliability and asset management tools enhance the quality of inspection data. By streamlining data capture and integration, these tools improve equipment reliability and provide actionable insights during both planning and execution phases.

  • Inspection Excellence: Pre-event inspections are crucial for compliance verification, risk identification, and reliability assessments. Effective inspection planning equips STO planners with accurate, actionable data to mitigate risks and enhance outcomes.


Best-in-Class Operations

Operational excellence lays the foundation for successful STOs. Operations teams contribute by ensuring reliable data, disciplined scope management, and precise execution strategies. Key practices include:

 

  • Reliable Data: High-quality operational data ensures that planners and stakeholders can make informed decisions. Reliable information is critical for creating accurate scopes and plans.

  • Scope Management: Operations teams guide the scope development process, balancing technical requirements with plant constraints. Their expertise ensures that scopes are comprehensive yet realistic.

  • System Sequencing and Milestones: A well-sequenced shutdown and startup process is essential. Clear, logical steps, supported by detailed milestones, enable the creation of an achievable schedule and plan.

  • Efficient Permit Issuance: During execution, operations teams must align permit processes with STO priorities. Streamlining this alignment helps prevent delays and keeps the project on track.

 

 

Best-in-Class Maintenance Organizations

Maintenance organizations are vital for STO success. To elevate their impact, focus on these key areas:

  • Strategic Planning: Maintenance teams should lead the effort to align plant needs with STO objectives. Their input ensures that work scopes address both immediate requirements and long-term reliability goals.

  • Advanced Tools: Technologies such as digitalized work orders, digital twins, and predictive analytics enable efficient planning and execution. These tools enhance visibility and coordination, reducing errors and rework.

  • Skill Development: Well-trained teams and contractors are essential for delivering high-quality work. Regular training programs ensure that personnel are equipped to meet the demands of STO events.


Conclusion

Achieving best-in-class STOs requires seamless collaboration across reliability, operations, and maintenance functions. Effective communication, supported by clear coordination across stakeholders, enables agile responses to challenges and ensures alignment with project goals. The outcomes include reduced costs, minimized downtime, enhanced safety, and sustained operational efficiency.

Mobideo’s STO readiness assessment tool is a digitalized solution designed to unify the entire organization. By verifying the completion of preparation tasks, collecting comprehensive data, and monitoring progress through well-defined KPIs, this tool ensures your STO strategy is both efficient and effective.

Elevate your STO processes by investing in best-in-class practices and tools, and experience the transformative impact of operational excellence. To learn more about MobideoSTO's Readiness Solution visit: https://mobideo.com/sto/addressing-the-complete-sto-lifecycle/ or reach out to info@mobideo.com