How to Optimize Downtime During a Turnaround or Shutdown

Industrial maintenance shutdowns are a short window, to investigate, inspect, and do all the necessary repairs and maintenance for an entire facility. The level of planning, implementation, and success all hinge on effective teams communicating and completing work simultaneously. Typically, there is more than one area or issue that needs to be addressed, and several teams of contractors need to be coordinated and scheduled for this short turnaround. Traditional methods often fall short, which lead to longer than desirable downtimes. It also overlooks critical areas due to logistical challenges and cost constraints.

Pacific Ropes, is providing multi-disciplinary teams that deliver effective solutions to ensure downtime is kept to a minimum by reducing the amount of time to access challenging work areas. This can expedite the scope of what can be accomplished in a 2 week shutdown. 

Challenges of Downtime

1) Neglected Areas: Areas of concern that are difficult to access are either neglected, or detected but not addressed due to time constraints of setting up scaffolding to reach the area. 

2) Multiple locations require simultaneous servicing: Numerous locations demand simultaneous servicing, each with unique work scopes ranging from inspections, welding repairs, asset installations, to confined space work, and more. Coordinating various teams in these areas for simultaneous work can lead to time constraints and reduced efficiency.

3) Complex work locations: Industrial facilities, are not all made the same. Specialized equipment, large machinery, sensitive areas, and structural design can present unique access challenges for work. Navigating these challenges add to potential longer downtime during a shutdown. 

4) Issues that require immediate attention: Some jobs are dependent on other areas or equipment being operational. Some issues need simultaneous maintenance or testing, and it is all dependent on quick and easy access. Other times, malfunctions may happen, and you need to gain quick access to a specific location to solve.

5) Unexpected Issues: Whether through inspections, or caused by a domino effect of resolving one issue but other issues arise as a result, maintenance issues are often full of unwelcomed surprises.

Strategies and Solutions To Optimize Downtime Efficacy 

1) Versatility and mobility to access areas of difficulty: 

Unlike scaffolding setups, rope access enables easy movement from one location to another, making accessing hard-to-reach areas a breeze. This agility eliminates the need for extensive setup times associated with traditional methods, streamlining the maintenance process and maximizing productivity during shutdowns. 

In one recent project, our team was asked to help reduce the reliance on scaffolding to access over 100 work locations. When our team assessed the scope, it was determined that scaffolding could be completely eliminated for the work scope, saving on equipment delivery/setup/dismantling for over 100 locations.

2) Comprehensive solutions with a multidisciplinary team of variety of trades/application skills:

Our expert teams are equipped to handle a wide array of tasks, from welding and inspection to installation, maintenance, pipefitting, confined space work, and even rescue operations. By consolidating these services, clients are not struggling with the hassle of coordinating multiple contractors, saving time, resources, and stress.

3) Dynamic and adaptable workforce to access complicated locations with minimal set up:

Scaffold set ups can be cumbersome in some scenarios, where it can contribute to a congested work area instead of creating access and areas of easy navigation. 

Our highly trained teams have the necessary skills and expertise to tackle even the most challenging environments. Out teams are capable of maneuvering around complicated machinery or accessing confined spaces, and ensuring that no maintenance task is too difficult to complete. 

4) Rapid access to critical areas:

During downtime, time is of the essence. Delays in accessing critical areas can have a domino effect, leading to extended downtimes and costly setbacks. With rope access services, rapid access is guaranteed. By maneuvering through complex structures, our teams facilitate inspections and repairs, enabling facilities to resume operations in a timely manner.

5) Seamless integration for unexpected repairs:

Unforeseen repairs are common during shutdown operations. Setting up access for such repairs can be time-consuming and labor-intensive. Pacific Ropes eliminates this with seamless integration of access and servicing unexpected repairs. Our agile teams can navigate to the areas of concern, assess or repair, minimizing unforeseen time. 

In a recent project, our teams have been able to address issues that were not in initial work scope such as emergent maintenance issues like valve replacements and nozzle repairs. These unplanned tasks were executed with precision and efficiency, minimizing future unexpected issues or maintenance time.

Explore Your Options

Industrial maintenance shutdowns are a necessity. But how this time is utilized can always be improved. From easy mobility and comprehensive solutions to dynamic workforce capabilities and rapid access to critical areas, our rope access services increases productivity during shutdown operations. Thorough maintenance procedures ultimately results in a productive facility reducing compounding stress of neglected areas, structures, and overall project management over the years. With Pacific Ropes, you can be assured of more effective and efficient methods, with our multi-disciplinary teams. If you're faced with a project that requires repairs and maintenance in a short demanding window, don't hesitate to reach out to us!