Plant turnaround is vital in process industry – to maintain consistent productive capacity, prevent accidents and improve safety at the plants. It is a scheduled stoppage of part or all of a plant’s operations for maintenance, to replace equipment, upgrade energy resources or maintain regulatory compliance.

Planning and managing turnarounds in plant environment can be complex and demanding; if turnarounds are not carefully planned and controlled, there might be issues and risks of serious budget overruns, schedule delays and negative impacts. Therefore, it is crucial to ensure the technical personnel are readily available and reliable for effective and coordinated turnaround activities.

INSTEP On-the-Job Learning (OJL) on Turnaround Management and Execution training is designed to provide structured training and guidelines for planning, managing, and executing process tasks related to Turnaround activities. The training was conducted using blended learning approach, with a combination of classroom and practical workshop modes, group discussions, and execution of Turnaround work at INSTEP live training plant: Upstream Downstream Training Plant (UDTP).

The OJL took learners on a 10-day journey that began with setting strategic objectives during which they carried out planning & preparations of plant turnaround, pre-shutdown, and shutdown. The learners also conducted extensive and guided hands-on practices, monitoring activities and audits during the learning journey.

The learners involved are INSTEP Technician Training Programme (TTP) learners, engineers, and technicians from INSTEP Operation & Maintenance teams as well as other selected technical executives from Operation Management backgrounds.

Throughout the training led by experienced facilitators and trainers, learners are able to hone leadership skills and teamwork spirits, as well as enhance their profound knowledge and skills in maintenance and safe shutdown practices.

En. Kamarozaman Husin, Head of INSTEP Technical Learning Excellence Division said in his closing remarks, “The OJL training encompasses a holistic package of the best practices in any turnaround project, which are fundamentals for technical personnel to discharge their obligations in operation and maintenance work. Our live training plant, UDTP, is a functional and operative platform which allows our staff and learners to strengthen their basics and enhance their capability to address strenuous circumstances in real plant environment safely and efficiently.”