Plant outages are necessary to perform scheduled valve and actuator repairs. They also give you the chance to assess your valves for bad actors and determine if any additional repairs or replacements are needed.
But every minute of downtime is a minute of lost productivity, and a minute of lost revenue. The key to minimizing this downtime and ensuring that your plant is back up and running at full capacity as soon as possible is proper planning. Here are three key steps to a successful plant outage.
1. Start pre-outage planning at least 4 to 6 months in advance
You know you will need an outage, so don’t wait for the last minute to get the ball rolling. Early planning will help you avoid any hiccups, like the parts you need not being available.
The parts delivery process for every valve manufacturer is different — often you can get parts in a couple of days (though you’ll likely have to pay expedited freight costs), but for some valve manufacturers, it can take up to a year. When possible, plan your outage several months in advance so you don’t risk your parts not showing up on time.
2. Schedule a walk down with the service company that will be doing the work
The walk down is arguably the most important element of pre-outage planning. This is when the service company will assess your needs and estimate the scope and cost of the work. The technicians will examine your valve historical data and identify what repairs are necessary and what parts they need to order.
The walk down is also when the valve technicians will determine if any special equipment is needed to perform the repairs. For example:
- Are your valves located such that scaffolding or rigging is required to reach them?
- Is any specific personal protective equipment (PPE) required?
If you don’t schedule a walk down to identify these special considerations, your technicians might show up to do the repairs only to discover they are missing essential equipment. They’ll either have to go back and get the equipment or be on standby until it can be delivered. Either of these options will cost you extra time and extra money.
3. Conduct a post-outage assessment
Following the outage, conduct an assessment to review how it all went.
- Were the repairs completed on time?
- Did the product come under budget?
- Did the outage go as planned or did you run into any unexpected problems, like bad actors you hadn’t identified in advance?
This assessment will help you identify gaps so you can plan better in the future.
This is also the time to update your historical and diagnostic records. We recommend using a valve management software like ValvKeep to track your valve data. You can use this information to schedule valve preventative maintenance and plan your future outages.
Are you planning an outage? Our factory-trained technicians have a solid track record of completing outage work on time and under budget. Contact us to learn how we can minimize your downtime and make your next plant outage a success.