Digital turnarounds: leading practice in LNG train turnaround management

Abstract

Most operators are painfully aware that an LNG train turnaround is a time-consuming, complex and expensive undertaking; however, few know why the majority of turnarounds repeatedly overshoot schedules and budgets.

The typical turnaround window is planned for 24–28 days, but in reality most take more than 33 days to complete. Why? The answer often is that one cannot plan for the unknown. This typical response masks many inconvenient truths.

There are many well-understood reasons for poor turnaround performance, including sub-optimal preparation, limited execution control, silo mentality within the organisation, inaccurate asset data, late inspection reports, and lengthy drawing-update processes. Furthermore, turnaround managers are frustrated by the lack of visibility on progress and the poor quality of information that surfaces when it is too late.

Digital Turnaround is a new concept that can significantly improve performance and consists of several elements:

• asset analytics allowing operators to know the status of the asset data;

• predictive models to more accurately define scope;

• mobile management dashboards giving a near real-time view on progress;

• project systems fully integrated with the emergency response plan;

• mobile web-based interfaces for contractors to report progress, hours and HSE; and,

• wi-fi linking the schedule to detailed tracking of equipment, materials and contractors.

Digital Turnaround creates new possibilities to execute efficient and safe turnarounds. In this extended abstract the authors share their experience and lessons learned from recent Digital Turnarounds, resulting in the reduction of turnaround durations of more than 10 days, cost reductions of up to 40%, and improved safety performance.