how to use the tools

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Outage Fundamentals

How to use the tools

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Zone Outage Control™Will reduce cost and schedule by 10% for

three outage cycles.

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For example:

An outage cost of$3,000,000

An outage duration of

21 Days

An down day cost of

$50,000

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Zone Outage Control™ will save you

10% on cost or$300,000

10% on schedule or2.1 days at $50,000 a

dayor $105,000

For a total savings of

$405,000

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Zone Outage Control™ will

give you cost to date and cost to

finish 4 hours after the end of each shift with minimal effort.

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Zone Outage Control™ will reduce and eventually eliminate downtime due to poor outage close out. (100% availability for 18

months post outage)

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Boiler BookOrganization of

information (remember the

waltz)

All the information in

one place

Inspection documents

creation

Material and spares

ordering

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Working ScheduleFirst schedule the

shutdown/open and ready for work hour by hour• Get ops / maintenance /

engineering to give you their schedules

Then schedule the zones• Get the contractors and

lead man to develop a shift by shift task list and manpower loading then review

Then schedule unit testing• Get ops to give you

their timing

Then the start up• Get ops to give you

their timing

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Get everyone to buy in after the schedule is roughed in.

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Get commitment from everyone.

Upper Management

Management

Operations Maintenance

Engineering Safety All Contractors

All Lead Men

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Cost Control Dashboard

Take the working schedule and monazite it shift by shift and contractor by contractor in excel

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Follow the outage calendar.

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Get all the mental soak time you can

Constantly mentally rehearse

everyone’s part.

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Build a team out of different departments and companies.

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Have as many lead men and contractor meetings and lunches before the outage.

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Everyone needs to know their part.

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Choose an Outage Manager.

The Outage Manager chooses a night manager.

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Once the bell rings

In shutdown / LOTO / open and ready for work, the

outage manager needs to be there for each hand off

of work.

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Daily outage meetings.Twice a day (morning and night)

With leadmen and contractor foreman.

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SAFETY FIRSTNear

misses written

Near misses closed

General concerns

Site conditions

Upcoming dangerous

tasks

Contractor coordinatio

n

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Have a zone chart.Only talk about what will be done in next 12

hoursNever accept “That should be done by shift

change”

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Make everyone aware that they

need to answer the question you asked

or else

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Collect timesheets at every meeting.

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Buy donuts and coffee.

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Outage meeting

should only be 15

minutes to half an hour.

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Create a team of

all involved.

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Call the ball when it’s time to shift

between assess

and elbows

and close outs.

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PRINT OUT ENDING

MILESTONES IN LARGE PRINT AND

HANG THEM EVERYWHERE.

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Inspections and Outage

ReportReview all as found sheets

Create work scopes from as

found inspection documents

Get all close out/as left documents

Keep all the originals in a three

ring binder and that’s your outage

report

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As outage manager, keep

these basic principles in

mind:Keep everyone

focused on what’s next and the end of

the outage

Declare when the outage is over (date and time) loudly as

possible days before your appointed date

and time

If a job site looks like a mess it is, stop and get it right or you will

fight it all outage