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Turnaround Track — Course Outline

DRAFT · unverified

Status: DRAFT v0.1 outline | Unverified until owner sign-off. Follows Playbook DRAFT v0.2 (rule 1 transactions-plus-sources, rule 6 employer conflict of interest, section 3 lesson format applied at outline level). Audience: Both, Mechanical and Instrumentation & Electrical (I&E) Prerequisites: Flagship course modules on job planning, scheduling, and backlog and key performance indicators (KPIs), or equivalent experience TBD: owner to confirm Time: TBD: owner to supply

Source keys: [S#] and [map X] are public sources listed with URLs at the end. Transaction codes come only from the course transaction reference. Turnaround-specific practice (roles, milestones, scope freeze, critical path) has no source in the approved source set yet. Those items are marked [UNVERIFIED: no public source yet] and need a public source before they ship TBD: owner to supply.

Employer rule: Content is general industry practice from public sources only. [EMPLOYER REVIEW: owner to check that the structure, milestones and terms below don't mirror any employer's internal turnaround (TA) methodology, gate names, templates or lessons-learned.]

A turnaround (TA), also called a shutdown, is a planned outage of a unit or plant to do work that can't be done while it runs. This track uses SAP Plant Maintenance (SAP PM) for notifications, work orders, materials and confirmations, alongside the preventive maintenance (PM) program. Your site's procedures, permit rules and management of change (MOC) process override this course.

Lesson T1: The turnaround timeline and roles

  • Outcomes: Describe the phases of a turnaround from scope collection to post-turnaround review. Explain how the planner's and scheduler's roles change during a turnaround.
  • Step 1: Map the phases and who owns what.
    • What to do: Walk through scope collection, scope review and freeze, detailed planning, materials and contractor preparation, scheduling, execution and close-out. Identify who owns each phase at your site.
    • SAP transactions: none, non-system step
    • Sources: [UNVERIFIED: no public source yet] TBD: owner to supply a public source on turnaround phases. General planning principles: [S17].
    • Craft notes: Mechanical usually carries the largest share of turnaround hours (exchangers, vessels, rotating equipment). I&E work is often on the critical path at start-up (loop checks, safety instrumented system (SIS) testing) Unverified.

Lesson T2: Building the scope and work list

  • Outcomes: Collect outage-only work from the backlog. Build a reviewed scope list with a clear reason for each item.
  • Step 1: Pull outage work from the backlog.
    • What to do: Filter open notifications and orders for work that needs the unit down. Use the Backlog Tracker's "Outage needed" column.
    • SAP transactions: IW29, Display Notifications (list); IW39, Display PM Orders (list); IW38, Change PM Orders (list)
    • Sources: [map E] SAP Community, Standard SAP Plant Maintenance Reports
    • Craft notes: Mechanical scope often comes from inspection findings and run-to-turnaround repairs. I&E scope often includes SIS proof tests that can only be done offline [S5] [S7].
  • Step 2: Raise missing scope and review it.
    • What to do: Raise notifications for scope that isn't in the system yet. Review every item for a reason to do it now. Agree a scope freeze date and how late additions are approved [UNVERIFIED: no public source yet].
    • SAP transactions: IW21, Create PM Notification - General; IW22, Change PM Notification
    • Sources: [map I] tcodesearch PM list; [S11] SAP Learning, Creating Orders
    • Craft notes: none beyond Step 1.

Lesson T3: Planning turnaround work orders

  • Outcomes: Build turnaround work orders with operations, work centers, hours and components. Identify materials that need early ordering.
  • Step 1: Create and plan the orders.
    • What to do: Create orders from the scope notifications. Add operations, work centers, labor estimates and components, the same way as for routine work, but with more attention to sequence and access.
    • SAP transactions: IW31, Create Order; IW32, Change Order; IW33, Display PM Order
    • Sources: [S11] SAP Learning, Creating Orders; [map I]; [S19] Doc Palmer on estimating
    • Craft notes: Mechanical orders often need scaffold, insulation, rigging and blinding steps. I&E orders often need calibration equipment, loop drawings and vendor support.
  • Step 2: Check materials and order long-lead items.
    • What to do: Check stock for every component. Raise purchase requisitions (PRs) for non-stock items early enough for delivery. Lead-time rules are your site's call.
    • SAP transactions: MMBE, Stock Overview; ME51N, Create Purchase Requisition
    • Sources: [S12] SAP Learning, Planning Material and Services; [map D]; [map J]
    • Craft notes: Mechanical long-lead items are often bundles, gaskets, valves and seals. I&E long-lead items are often analyzers, control valve trim and relays Unverified.

Lesson T4: Permits, isolation and multi-craft sequencing

  • Outcomes: Plan permits and isolations for a group of turnaround jobs. Sequence Mechanical and I&E work on shared equipment.
  • Step 1: Plan permits and isolations.
    • What to do: Identify permit types and isolation points for each job per your site's rules. Group jobs that share an isolation boundary. Never plan work that shortcuts permit or isolation steps.
    • SAP transactions: If your site uses SAP permits: IPMD, Maintain/Display Permits; IPM2, Change Permit; IPM3, Display Permit [UNVERIFIED: third-party sources only]. Classic Work Clearance Management (WCM): WCTA, Create Work Approval; WCTK, Create Work Clearance Application [UNVERIFIED: third-party list only]. SAP S/4HANA Permit to Work: Manage Work Permits (Fiori app F6579) Unverified; PTWMASSGEN, Mass Generation of Permit to Work Objects. Otherwise: none, non-system step.
    • Sources: [S15] OSHA 29 CFR 1910.147 (lockout/tagout (LOTO); US only); [map Q] [map R] [map S] (permit and WCM codes); [map L] [map M] (S/4HANA Permit to Work)
    • Craft notes: Electrical isolation by an authorized person usually comes first and restoration last. I&E testing of SIS functions needs bypass authorization per your site's process [S7].

Lesson T5: Contractor and services planning

  • Outcomes: Plan contractor scope and external services as part of the turnaround work orders.
  • Step 1: Plan external services and contractor scope.
    • What to do: Decide which work goes to contractors. Plan external services on the orders the way your site does. Define what each contractor needs from you before mobilization TBD: owner to supply.
    • SAP transactions: IW32, Change Order (operations and services) [UNVERIFIED: how services are planned depends on configuration]; ME51N, Create Purchase Requisition
    • Sources: [S12] SAP Learning, Planning Material and Services; [map I]; [map J]
    • Craft notes: Specialist I&E and electrical contractors (e.g., relay testing, analyzer vendors) often need longer notice Unverified.
    • [EMPLOYER REVIEW: owner to check this lesson doesn't reflect any employer's contractor strategy or contract terms.]

Lesson T6: Scheduling the turnaround

  • Outcomes: Build a turnaround schedule with logic between jobs. Explain what the critical path is and why it matters.
  • Step 1: Load the work and check capacity.
    • What to do: Pull turnaround operations into an order and operation list. Check craft capacity against the planned hours.
    • SAP transactions: IW37N, Change Orders and Operations; CM25, Capacity Leveling - Variable
    • Sources: [map E]; [S16] SAP Learning, Configure Work Centers
    • Craft notes: Plan Mechanical and I&E as separate crafts, with the handoffs shown as logic.
  • Step 2: Build logic and find the critical path.
    • What to do: Link jobs in the order they must happen, and identify the longest chain of dependent work. Many sites use a dedicated scheduling tool for this. See the Microsoft Project and Primavera P6 course outlines.
    • SAP transactions: none, non-system step (done in your scheduling tool)
    • Sources: [UNVERIFIED: no public source yet] TBD: owner to supply a public source on critical path scheduling
    • Craft notes: Start-up activities (I&E loop checks, SIS testing, Mechanical run-in) often sit at the end of the critical path Unverified.

Lesson T7: Tracking execution

  • Outcomes: Record daily progress and actual hours. Handle emergent (newly found) work without losing control of scope.
  • Step 1: Confirm work and track progress.
    • What to do: Confirm hours and completion each shift or day per site practice. Raise notifications for emergent work and route them through the late-scope approval agreed in T2.
    • SAP transactions: IW41, Individual Time Confirmation; IW44, Collective Time Confirmation Without Selection; IW48, Collective Time Confirmation With Selection; IW47, Confirmation List; IW21, Create PM Notification - General
    • Sources: [map H] / [S22] SAP Learning, Confirming Notifications and Orders; [map I]
    • Craft notes: Mechanical emergent work often comes from inspection findings once equipment is open. I&E emergent work often shows up during loop checks before start-up Unverified.

Lesson T8: Close-out and post-turnaround review

  • Outcomes: Close turnaround orders cleanly. Run a post-turnaround review that feeds the next scope and the PM program.
  • Step 1: Close out the orders.
    • What to do: Make sure confirmations, measurement readings and goods movements are complete, then complete the orders per site practice. What technical completion (TECO) does to open reservations and purchase requisitions depends on configuration. Check yours Unverified.
    • SAP transactions: IW42, Overall Completion Confirmation (order-based); IK11, Create Measurement Document; MIGO, Goods Movement [UNVERIFIED: movement types]; IW32, Change Order (TECO)
    • Sources: [map H] / [S22]; [S23] SAP Help, Completion Confirmation; [map J]; [S24] SAP KBA 2913800 (written for production orders, not PM orders) Unverified
    • Craft notes: Record Mechanical as-found condition and I&E as-found/as-left test results. They drive future intervals.
  • Step 2: Review and feed forward.
    • What to do: Review what was added late, what slipped and why. Turn findings into task list and maintenance plan changes, and into scope for the next turnaround.
    • SAP transactions: MCI5, PMIS: Object Damage Analysis; MCI7, PMIS: Breakdown Analysis (Plant Maintenance Information System (PMIS)); IA06, Change General Maintenance Task List; IP15, Change Maintenance Plan (list)
    • Sources: [map E]; [map A]
    • Craft notes: I&E proof test results feed SIS interval reviews through your site's safety process, not the planner alone [S7].
  • Backlog Tracker (../templates/backlog-tracker-README.md)
  • Weekly Scheduling Board (../templates/weekly-scheduling-board-README.md), adaptable to daily turnaround tracking Unverified
  • Turnaround coordination sheet TBD: owner to supply, not yet built

Disclaimer

Adapt to your site's SAP configuration and procedures. Not affiliated with or endorsed by SAP SE. SAP and SAP PM are trademarks of SAP SE. © TBD: owner to supply year [PLACEHOLDER: legal entity].

Sources

Verification log

  • Verified by: [owner] | Date: [ ] | Notes: [ ]

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