ShutdownSMART

Define and document the high-level objectives, boundaries, and key deliverables for the shutdown.

Present the draft shutdown scope and plan to the steering committee for approval and feedback.

Finalize and distribute the approved shutdown plan to all relevant stakeholders.

Input all identified shutdown activities, durations, and dependencies into the project scheduling software.

Ensure all necessary Bill of Materials and spare parts are identified, procured, and staged.

Confirm availability and allocation of internal and external personnel required for the shutdown.

Verify that all necessary tools, lifting equipment, scaffolding, and safety gear are available and certified.

Ensure all required work permits, isolation plans, and Lockout/Tagout (LOTO) procedures are prepared and approved.

Conduct safety orientation and specific hazard briefings for all personnel involved in the shutdown.

Finalize and communicate all identified risks and mitigation strategies for shutdown activities.

Safely isolate power to equipment and verify zero energy state using LOTO procedures.

Disconnect, label, and safely route existing and new electrical cables.

Remove and replace faulty electric motors, ensuring proper alignment and connection.

Perform megger tests and visual inspections on electrical insulation to ensure safety and reliability.

Carefully remove and clearly label all instruments and associated tubing/wiring before maintenance.

Install new instruments, ensuring correct orientation, connections, and sealing.

Calibrate instruments and perform loop checks to verify signal integrity and functionality.

Precisely align rotating equipment shafts (e.g., pumps, motors) using laser alignment tools.

Remove old bearings and install new ones, ensuring proper lubrication and seating.

Drain, flush, and refill gearboxes with specified lubricant, checking for wear.

Safely remove, inspect, and test critical valves for wear and proper operation.

Replace damaged or worn hydraulic hoses and fittings, ensuring correct pressure ratings.

Inspect and repair any structural supports for piping, equipment, or platforms.

Prepare weld joints and apply necessary preheating according to WPS.

Perform high-quality welds on critical components as per approved procedures.

Apply PWHT to welds as required by code and WPS.

Flush and clean process fluid circuits to remove contaminants before recommissioning.

Perform functional tests on critical safety systems (e.g., ESD, fire suppression).

Execute final checks, system commissioning, and formal handover to operations.