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CM 3335 - Maintenence and Turnarounds final > Final > Flashcards

Final Flashcards

1
Q

(T/F) TAR’s are inherently expensive, sometimes as much as half of the annual budget for the site

A

true

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2
Q

TAR’s are not frequent events. this results in __________ who will be involved in preparing for and managing the next TAR event

A

a fairly large turnover of personnel

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3
Q

this deliverable involves the gathering, evaluation, and archiving of key TAR data and sets the stage for the next TAR

A

TAR close out

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4
Q

data collection after execution for continuous improvement must be done in a timely manner while people are still accessible and data is fresh. names sometimes given to these process events are ______, _____, or _______.

A

critiques, look-backs, and continuous improvement sessions

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5
Q

(T/F) capturing data for continuous improvement not only includes the execution phase but the preparation and planning phase as well

A

true

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6
Q

once execution of the TAR plan has been completed, it is extremely important that time is taken to evaluate the effort and capture data around ______, ______, and ______.

A

success of achieving TAR goals or KPIs, areas of strength that need to be sustained, and areas of opportunity to improve

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7
Q

depending on the size of the outage, post TAR work can take as long as _______ post and as little as _______ post.

A

12 weeks, 3-4 weeks

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8
Q

(T/F) post TAR work starts directly after the TAR completion

A

false, after the unit has started up and is running

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9
Q

during execution, the key platers attend meetings from the TAR ______ team and TAR ______ team; adjustments are made basis the data being measured

A

management and planning

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10
Q

(T/F) during execution, update meetings are held bi-weekly to review safety stats, environmental compliance, progress, cost, and other key elements of the TAR.

A

false, daily

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11
Q

TAR execution is managed by setting up and maintaining proper _______.

A

project controls

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12
Q

what are the 4 phases of a TAR execution?

A

unit shutdown and equipment preparation, TAR maintenance window, equipment turnover and commissioning, and unit inventory and startup

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13
Q

the ability to achieve success in execution is directly proportional to several factors: ? (6)

A

size, adoption of TARPG, adherence to TARPG deliverable compliance, effective governance, clear goals and organizational alignment, and effective project controls

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14
Q

(T/F) some TAR’s may execute over 500,000 manhours in a 40-day window, with manhour levels peaking over 1500 craftspersons- they involve working long hours for many days straight

A

true

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15
Q

(T/F) by nature, TAR’s are very intense, high activity events that occur in a very compressed timeframe

A

true

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16
Q

being environmentally ______ is key to achieving a successful execution of a TAR

A

compliant

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17
Q

(T/F) conducing a TAR safely and without injuries is a big challenge but paramount

A

true

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18
Q

pre and post TAR work being included in the TAR plan and coded so the work can be segregated and scheduled separately allows for what?

A

quantifying the amount of resources and time it will take to complete preparations/post TAR activities

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19
Q

(T/F) pre and post TAR work is not included in the TAR plan and is coded so the work can be segregated and scheduled separately

A

false, is included

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20
Q

depending on the size of the outage, pre TAR activities can start as early as _______ out and as little as _______ out.

A

12 weeks, 3-4 weeks

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21
Q

(T/F) pre TAR work should start prior to the TAR with enough time to complete all preparatory activities prior to the unit shutdown

A

true

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22
Q

during the TAR plan alignment and agreement stage, contingency plans are also reviewed and discussed for clarity and agreement. the deliverable from this event is a _________ that has been agreed to by all players

A

final TAR plan and schedule

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23
Q

this is the stage for all elements of the TAR plan and schedule to be finalized

A

TAR plan alignment and agreement

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24
Q

this exercise consists of conducting a walk thru or simulation of the TAR plan and schedule. key players are assembled with each representing their area of responsibility for the TA- each walks through their respective section of the TAR plan and schedule, shift by shift to gain alignment and identify any last gaps.

A

TAR plan alignment and agreement

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25
Q

___________ are drafted and used to measure progress on addressing items by the TAR planning and management teams; a final book is assembled with the key threats and plans being published and communicated to the entire site

A

mitigation and contingency action plans

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26
Q

the design or intent of threat assessment is to assemble ______ to identify and risk-rank the threats that may occur during the outage and have a negative impact on the effort

A

key execution staff personnel

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27
Q

________ activities are optimally performed following development of the TAR plan and schedule and 2 months prior to the start of the outage.

A

threat assessment

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28
Q

if there is an overage on the final estimate, a business decision must be made to either obtain the funds to cover the difference, or reduce the amount of work scope to be performed. if funding is increased, impact is negligible to the TAR plan. however, if work scope reduction is chosen, potential impact to the TAR plan is directly proportional to the _________ and _________.

A

size of the reduction and remaining time to the outage

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29
Q

once the TAR plan has been scheduled with a resource loading control plan, a _______ can be generated by taking manhours from the manpower loading control plan and applying the corresponding hourly rates to each craft type

A

final estimate

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30
Q

once resources have been leveled, the CMMS can then be used to generate ________, which quantify the numbers of craft types by shift, by day for the entire job; this provides a control mechanism to be used in managing craft numbers each day of the TAR and will also be used to generate the final budget/estimate

A

manpower histograms

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31
Q

once the critical path has been determined, resources can then be “_______” on all non-critical path activities; this reduces the total number of craftspersons needed to a more manageable number to complete the work still inside the duration dictated by the critical path

A

leveled

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32
Q

an additional parallel path through the critical path network with the total durations shorter than the critical path is called ________

A

sub-critical (or non-critical)

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33
Q

(T/F) a project can have several, parallel, near critical paths

A

true

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34
Q

(T/F) there can be float on the critical path

A

false, there is no float on the critical path

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35
Q

any delay of an activity on the critical path directly impacts the _________.

A

planned project completion date

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36
Q

the critical path determines the ______ to complete the project

A

shortest time possible

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37
Q

the sequence of project network activities which add up to the longest overall duration

A

critical path

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38
Q

______ calculates the longest path of planned activities to logical end points or to the end of the project, and the earliest and latest that each activity can start and finish without making the project longer; it determines which activities are critical and which have total float

A

critical path method

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39
Q

when the TAR plan is ready to be scheduled (activity sequencing) and resource loaded (leveling) using the CMMS and EVM, a scheduling method called _______ is used; this was developed in the 1950s by James E. Kelley, Jr. of Remington Rand Company, and Morgan R. Walker of DuPont.

A

critical path method (CPM)

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40
Q

______ are an integral player in TARPG and their involvement early on and full time is essential to achieving success in safely executing the TAR

A

operations

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41
Q

failure to accurately align the timing of equipment availability with the mobilization of the workforce will result in many manhours being wasted with workers waiting on equipment to be turned over. this can result in ______ and _____.

A

budget overruns and schedule non-compliance

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42
Q

decommissioning and commissioning schedule
along with thorough procedures with sufficient detail, operations need to lay out an accurate _______ that will provide the necessary data to schedule the maintenance activities of the TAR plan

A

shut down and start up process

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43
Q

due to the infrequency, complexity, and level of responsibility TAR’s present to operations, it is imperative that they have ___________ to safely guide the operators step by step through the

A

thorough procedures with sufficient detail

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44
Q

(T/F) once the unit is secured and prepared, operations is responsible for permitting all of the work activities scheduled to take place in their unit

A

true

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45
Q

(T/F) most facilities run their units for several years between TAR’s

A

true

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46
Q

______ have the responsibility to ensure safe and reliable operation of each of the units; they have ultimate control over all activities within their respective unit areas.

A

operators

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47
Q

_______ is the discipline that operates each of the units or assets within a facility. they staff each of the units, round the clock with personnel- these workers are known as ________.

A

operations, operators

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48
Q

planning for materials (take offs) involve identifying the ______ to execute each job as well as the proper _________.

A

materials required, design specifications

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49
Q

entering WBS and coding at the task level of each job plan in the CMMS tool allows the scheduler to extract management reports; the TAR coordinator and manager use these reports to measure _______ and “drill down” to uncover root causes and contributing factors to non-
conformance

A

progress (earned value)

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50
Q

a “planning and scheduling” tool is normally used in EVM- this planning and scheduling tool is sometimes referred to as _______ and incorporates EVM.

A

computerized maintenance management system (CMMS)

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51
Q

earned value management provides ______ data for project decision making

A

quantitative

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52
Q

the _______ is an essential component of earned value management and serves as a reference point for all EVM related activities

A

project baseline

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53
Q

earned value management issued on the cost and schedule control and can be very useful in _________

A

project forecasting

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54
Q

most companies utilize a system called ________. it helps project managers to measure project performance; it is a systematic project management process used to find variances in projects based on the comparison of work performed and work planned

A

earned value management (EVM)

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55
Q

involved in executing the event, each TAR job has ben individual job plan built containing _______ and _______.

A

accounting for the thousands of sequenced activities

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56
Q

once the planning team receives ______, each project is planned and estimated
accurate identification of the work scope and individual job plans

A

issue for construction

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57
Q

in project engineering and detail design there must typically be approval upon the ______ from the project stakeholders

A

completion of each stage

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58
Q

the stage of project engineering and detail design where detail design is complete- planning scheduling, ordering materials commences

A

issue for construction (IFC)

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59
Q

the stage of project engineering and detail design where the detail design quantifies the project
cost for management approval

A

issue for approval (IFA)

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60
Q

the stage of project engineering and detail design where there is preliminary design funding and scope definition

A

concept approval

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61
Q

the stage of project engineering and detail design that provides initial funding for better definition on scope clarity

A

front end loading (FEL)

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62
Q

the stage of project engineering and detail design where there is the initial decision to pursue the project

A

project initiation

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63
Q

the deliverable of project engineering and detail design is typically called “_________” or “__________” drawings; they are then used by the planning team to estimate, plan, schedule, and order materials for the project

A

construction packages or issued for construction (IFC)

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64
Q

the different stages of engineering allow for ________ as clarity for the project increases regarding scope, and detail design

A

decision making for funding

65
Q

engineering must be done prior to ______ and requires a large amount of work, broken into different stages

A

planning and scheduling

66
Q

for events where there is a large amount of capital project work, _______ will be employed to provide the added resources to complete the engineering and design

A

third part engineering firms

67
Q

most TAR’s will have capital projects that are to be installed as part of the event; the magnitude of project work is normally driven by the _______ outlined in the asset reference plan

A

capital improvement strategy

68
Q

_______ are designed to identify the status of preparation for the event based on industry best practices; these exercises normally take _____ and involve all groups involved in preparation for the TAR.

A

preparedness assessments

69
Q

(T/F) typically, preparedness assessments don’t engage third party involvements or facilitation from subject matter experts.

A

false, do engage

70
Q

(T/F) sometimes preparedness assessments may be called readiness reviews, stage gate reviews, or health checks. they can range in the number of assessments conducted and timing based upon the size of the TAR

A

true

71
Q

with TAR preparedness, a failure to successfully deliver one of the process elements can have negative implications in executing the event. the severity of the impact will vary depending on the _____ and _____ of process deliverable in question

A

type and tardiness

72
Q

TAR process deliverables are sequentially ______ and _______

A

dependent and time driven

73
Q

early identification of the correct procurement strategy
competition for the right resources requires ________ for the work to be contracted and selection of best available contractors

A

price

74
Q

with a limited amount of contractors and resources (craftspersons) available, it becomes important to _______ the work to be performed with the best contractor available, at fair market

A

quantify and match

75
Q

larger events require bringing in multiple contractors from “_________” the facility to supply the expertise and numbers of resources anticipated to complete the work

A

outside

76
Q

the more work being performed during the TAR will require more _____ and essentially correlates into more ________; smaller events typically can be managed with the “_______” maintenance workers and contractors

A

workers, contractors, in house

77
Q

the effort required contracting and procurement strategy is directly proportional to the __________.

A

size and complexity of the TAR event

78
Q

(T/F) if it is determined that permitting or permit modification is required, this can be a long process and has the potential to impact the TAR by delaying it

A

true

79
Q

(T/F) all TAR’s require permits or permit modifications

A

false, not all

80
Q

the environmental permitting application process requires ______ to make determinations early on if any proposed modifications being made to the asset will increase its emissions above what it is permitted for.

A

specialty resources

81
Q

(T/F) all industries are required by law to be in compliance with the applicable rules and regulars from all state and federal agencies

A

true

82
Q

not having an accurate and complete work scope greatly diminishes the probability of developing a _______ and thereby makes it highly unlikely the outage will be successful

A

comprehensive TAR plan

83
Q

(T/F) budget alignment activities are time consuming and can have a large impact on planning efforts if not resolved quickly

A

true

84
Q

in some cases where a scope reduction is decided upon, it may be necessary to conduct another asset reference plan validation to determine if __________; failure to recognize this could result in an unidentified threat causing an unplanned _______ during the subsequent run length

A

the run time between TAR’s is still accurate, shutdown

85
Q

establishing an accurate budgetary estimate early on allows for any gaps or disconnects to be identified and decisions made to either ________ or _______

A

increase funding, reduce work scope

86
Q

accuracy in establishing TAR estimates is directly proportional to what key variables?

A

completeness of the work scope, accuracy of the work scope, and adequate time to estimate the work scope

87
Q

typical budget setting process for most sites involves a _______; that means the budget for the TAR is set well in advance and the timeframe for the opportunity to revise and/or make changes is very ________.

A

5 year plan, limited

88
Q

capital project submission can take a considerable amount of time and because it involves installation of new equipment, it cannot be properly estimated and planned until ___________ with construction drawings being supplied to the planners

A

the engineering is completed

89
Q

(T/F) most capital projects require some level of engineering to ensure proper design and specification requirements

A

false, all

90
Q

this deliverable is similar to work scope freeze in that it is designed to allow adequate time for engineering, estimating, and planning of capital projects

A

capital projects submission

91
Q

once the work scope is frozen, _______ are held between planners and TAR work request writers to discuss each _____ and ensure ______ around what work is being planned, any special requirements, threats, and potential discovery items.

A

review meetings, job, alignment

92
Q

a failure to adopt or enforce the scope freeze deliverable can present major implications by not being able to _________.

A

put a plan in place

93
Q

the key driver of the “scope freeze” element is the need to have TAR work ________ far enough in advance to allow enough time for proper estimating, planning, scheduling.

A

quantified

94
Q

the “______” deliverable involves placing a “cut off” date on TAR work requests being submitted for review and approval. work submitted after this cut off date is classified as “_______” or “added” work and is handled utilizing a different review and approval process.

A

scope freeze, addenda

95
Q

inspectors capture their recommendations by drafting _______- these will contain all of the key data on the equipment/piping systems required to ___________ the work.

A

TAR work requests, estimate and plan

96
Q

(T/F) post evaluation, inspectors make repair recommendations basis their findings. this may include further inspection methods, which may be performed while the asset is still running

A

false, cannot be performed while the asset is still running (can only be completed when shutdown)

97
Q

(T/F) the individual certification programs are based on the industry-developed standards that are recognized and used with confidence worldwide

A

true

98
Q

API inspectors must complete API’s ________ for each of the areas of their particular field of expertise

A

individual certification program

99
Q

as data is collected for inspections, it must be evaluated and interpreted by qualified personnel. these individuals are commonly referred to as ________. They are the leading authority in the petroleum and petrochemical industry regarding the development of equipment and operating standards.

A

API (American Petroleum Institute) inspectors

100
Q

(T/F) the information-gathering activities of inspections are conducted by trained qualified technicians and many times require additional support to be performed

A

true

101
Q

(T/F) all inspection methods are classified as “NDE” or “non-destructive evaluation”

A

false, most all

102
Q

in order to identify the proper work scope to be included in the TAR to achieve operation during the next TAR run length, ______ activities are required to evaluate and quantify the condition of equipment and piping systems.

A

inspection

103
Q

the TAR schedule provides the platform for the TAR ______ team to “set up” or “apply” the TAR _______ and timing to each TAR.

A

management, process key deliverables

104
Q

comprehensive operations and maintenance strategies, when integrated with __________ from other units or assets within the facility, sets the TAR schedule for the site.

A

asset reference plans

105
Q

one of the key deliverables from a comprehensive operations and maintenance strategy, “________________”, is driven by quantifying how long the unit can safely and efficiently run without having to experience an unplanned shut down or slow down. this sets the length of time between TAR’s.

A

unit run lengths between turnarounds

106
Q

a principal element to achieve successfully running facilities safely and efficiently for planned durations is driven by having a _______ for each asset (unit) within the facility

A

comprehensive operations and maintenance strategy

107
Q

(T/F) the ability of manufacturing facilities in the refining, petrochemical, power generation, and paper industry to successfully run their facilities safely and efficiently for planned durations of time is a basic requirement to meeting their business plan

A

true

108
Q

deliverables are sometimes called _____, ____, _____, etc. these tools provide a visual aid within a structured framework that allows for sites to maintain the _______ needed to meet the requirements.

A

dashboards, stop light charts, milestone trackers, discipline
examples of the monitoring tools used for they key TAR

109
Q

many companies have adopted some type of ______ for the key TAR deliverable; this allows for effective measurement and is very helpful in management decision making.

A

monitoring tool

110
Q

depending on the size of the TAR, initial TAR process deliverable milestones can start as early as _______ months prior to the start of execution

A

12-18

111
Q

most TAR process deliverable milestones are _______- this equates to completing the preceding milestone before you can effectively complete the following ones.

A

sequentially dependent

112
Q

most of the ______ (areas) from within the facility are involved in preparing and planning for the event. this requires a strategic ______ (procedure) be in place to manage the multitude of required preparation deliverables that are ________ (milestones).

A

disciplines, process, time dependent

113
Q

to develop a comprehensive plan for TAR’s requires a significant amount of _________- this dictates that preparations start well ahead of the actual execution date of the outage

A

lead time

114
Q

during TAR execution, ______ will progress activities and run management reports on key metrics. these reports will be used by the TAR ______ and ____ teams to monitor progress and
make decisions to manage the outage

A

project controls, planning and management

115
Q

because there are multiple individuals involved in managing project controls, the need for _______ in theory and application is important. to achieve this, most organizations develop and adopt a project controls ______ document.

A

consistency, premise

116
Q

(T/F) project controls are typically established and managed by the TAR coordinator, planner, scheduler, and cost engineer.

A

true

117
Q

(T/F) project controls are typically established and managed by the TAR coordinator, planner, scheduler, and cost engineer.

A

true

118
Q

for effective project controls to be implemented, when must they be established and set up?

A

early stages of TAR preparation

119
Q

project control is mainly concerned with the ______ of the project, such as quantities, time, cost, and other resources.

A

metrics

120
Q

management action, either preplanned to achieve the desired result or taken as a corrective measure prompted by the monitoring process.

A

project controls

121
Q

(T/F) during the outage, the TAR planning team meets once a day to “turnover” between day shit and night shift in managing the TAR.

A

false, twice a day

122
Q

(T/F) TAR planning team members will be assigned to either day or night shift along with additional support personnel.

A

true

123
Q

typically, the TAR planning team will transition into a(n) ______ role during the outage and be responsible for their ______.

A

execution, respective discipline areas

124
Q

the TAR ______ team is responsible for communicating status updates to the TAR management team along with elevating issues requiring resolution at a higher decision making level

A

planning

125
Q

the TAR planning team meets on a weekly basis to maintain ______, work through _______, and progress _______ to TARPG deliverable milestones

A

alignment on key issues, problems, compliance

126
Q

(T/F) TARPG deliverable milestones are all time sensitive and sometimes overlap from one discipline’s area of responsibility to another

A

true

127
Q

each TAR planning team member has specific ________ they are responsible for

A

process deliverables

128
Q

(T/F) all TAR planning team members are part time with responsibilities of day to day operations and maintenance activities.

A

false, some are full-time

129
Q

the ________ consists of the different area disciplines from within the site that represent their departments in managing TAR’s, including the site’s maintenance contractor.

A

TAR planning team

130
Q

the TAR management team is responsible for elevating issues and problems to the TAR leadership team requiring _________.

A

resolution at a higher decision making level

131
Q

(T/F) the TAR management team meets monthly to monitor progress and compliance to TARPG deliverable milestones and keeps the TAR leadership team updated

A

false, bi-weekly

132
Q

(T/F) the TAR management team has decision-making authority over the TAR planning team and gives specific guidance on TARPG issues.

A

true

133
Q

the TAR management team has the responsibility of establishing goals or ______ for the TAR. they must ensure alignment within the site of the goals.

A

key performance indicators

134
Q

TAR ______ team are responsible for measuring compliance of and meeting the TARPG deliverable milestones

A

management

135
Q

from within their respective departments, the ________ supply the resources needed to support TARPG, with either full time or part time members to the TAR planning team.

A

TAR management team

136
Q

(T/F) the TAR manager supervises departments whose main responsibility is the day to day operations and maintenance of the facility

A

false, all members of the TAR management team (excluding the TAR manager)

137
Q

the _______ consists of the different area managers from within the site who manage each of the key departments that support TAR’s, including the site’s maintenance contractor. (this includes the TAR manager as well as other areas from operations, contractor site manager, routine maintenance, inspection, engineering, capital projects, HS&E, procurement, finance, etc.)

A

TAR management team

138
Q

TAR _____ team is responsible for corporate communications regarding TARPG pertaining to the site

A

leadership

139
Q

(T/F) the TAR leadership team holds monthly update meetings to monitor compliance and provide general oversight and direction to the TAR management team.

A

true

140
Q

(T/F) the TAR management team has the final decision making authority and holds the TAR leadership team accountable to effectively manage TARPG for the site.

A

false, swap leadership and management

141
Q

with multitudes of competing priorities that can easily distract or detour TAR preparation activities, having a process with ________ being measured, allows for alignment in making data driven business decisions.

A

specific milestone dates

142
Q

due to the infrequency of TAR’s compared to day to day site operations and maintenance activities, it is the _______’s responsibility to ensure that turnaround process and governance (TARPG) be adopted and practiced

A

TAR leadership team

143
Q

the ______ consists of site senior management, including the site or plant manager, operations, engineering, maintenance, health, safety, and environmental, procurement, finance, etc.

A

TAR leadership team

144
Q

(T/F) with the high number of personnel involved, overlapping areas of responsibilities and decision making that pose a challenge to the effort must be eliminated

A

false, it is inevitable

145
Q

to effectively manage overlapping areas of responsibilities and decision making, cross-functional alignment on who, what, when, how, why, and why is crucial. to address this, TARPG incorporates an organizational structure that consists of a TAR _____, _____, and ______ team.

A

leadership, management, planning

146
Q

effective turnaround process and governance (TARPG) combines ________ (clear process deliverables and organizational structure), _______ (sequential dependency is meeting timing deadlines), ________ (monitoring compliance), and ________ (effective governance, priority decision making in a competing environment)

A

legibility, milestones, measurability, and controllability

147
Q

implementation of TAR’s require a tactical or strategic approach that incorporates a legible
_______ (deliverables), being managed b effective _______ (organization)

A

process, governance

148
Q

planning and scheduling can only be done properly if supported by a _______ being completed by different areas from within the state

A

multitude of activities (deliverables)

149
Q

(T/F) TAR planning and scheduling must take place weeks in advance of the actual execution date

A

false, months

150
Q

each TAR job must be: _______ (documenting the work to be performed), ______ (specific tasking steps, materials, and equipment to complete the work scope), ______ (quantifying the resources, manhours, and cost to execute the work), and ________ (assigning sequencing logic and integration of all jobs/tasking). these activities are called workscope development, planning and scheduling.

A

identified, planned, estimated, and scheduled

151
Q

to complete the tasks on time and within budget requires that a _____ be developed.

A

comprehensive TAR plan and schedule

152
Q

(T/F) to complete all of the TAR jobs in the shortest duration possible requires a handful of craftspersons working round the clock, in a fixed area of real estate, undertaking thousands of jobs tasks.

A

false, hundreds (sometimes thousands) of craftpersons

153
Q

major TAR’s for most facilities often equate from ____ to ____ of the sites annual operating budget.

A

1/3 to 1/2

154
Q

examples of ______ involved in the execution of TAR’s are welders, pipefitters, boilermakers, electricians, scaffold builders, instrument technicians, equipment operators, insulators, painters, and laborers

A

craft types

155
Q

the magnitude of a turnaround will determine the amount of ____ to complete the work, which once scheduled over a given period of days, will determine the number of _____ needed.

A

effort (man hours), workers (craft types)

156
Q

(T/F) TAR’s are mostly maintenance and reliability driven events with the goal to execute them
in the shortest timeframe achievable for the lowest possible cost.

A

true

157
Q

(T/F) TAR’s sometimes involve a single unit or asset within the facility, while at other times the may involve multiple units up to and including the entire facility

A

true

158
Q

a key element in company business plans for the refining, petrochemical, power generation, and paper industry. they are planned outages intended to undertake maintenance and inspection activities within the facility that cannot be conducted while units or assets are running

A

turnarounds (TAR’s)

CM 3335 - Maintenence and Turnarounds final (1 decks)

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