Shutdown & Turnaround Maintenance

Planned maintenance on process equipment that necessitates an interruption in normal operations is known as shutting down.

Predictive maintenance is one option, while breakdown maintenance is another.

Pre-Shutdown :

Activity in which a Do list is created, materials are purchased, human resources are organized & lined up, time and motion studies are done to calculate the amount of time required for a unit of work to be completed.

Shutdown :

Shutdowns can be scheduled and carried out as part of routine maintenance, operational efficiency, or process reengineering to increase output and profitability. Materials are collected, people are on the job, performing repairs and maintenance, and equipment is replaced or serviced systematically in this war-like scenario.


On average, a shutdown lasts 30–45 days, but this might vary considerably. The first day of Zero-Day begins with all operations being shut down, all equipment being cleaned with steam, and all manholes being opened for preliminary inspections. Then welders perform some repairs, the quality team evaluates the work using non-destructive testing, and the box-up is completed.

As the country's economy is heavily dependent on oil and gas, it is meticulously planned and performed in the shortest amount of time feasible, regardless of the age of the plant, the engineering process design - old or new technology, and so on.

Engineers and technicians plan work; then, the projects are built and put through a commissioning program to ensure that all the installations and production programs are working correctly.

     Post-Shutdown :

During the post-shutdown period, refinery reactivation processes are carried out.

Types of Shutdown :

An equipment item is typically shut down manually when no longer required for duty or during inspection or maintenance. During an emergency, a shutdown may also take place if:


Item Shutdown

An item shutdown will affect the specific piece of equipment, not the entire process or manufacturing facility.

To avoid the necessity of a process shutdown, connecting two pieces of equipment in parallel is possible.

Maintenance Shutdown

To make a piece of equipment safe for maintenance, a maintenance shutdown entails turning it off, draining it, and cleaning it.


Unit Shutdown

An entire facility cannot be shut down when a single process unit is shut down. So that downstream processes can continue to work even when a unit is down.


Total Shutdown

A complete shutdown will bring the entire facility to a halt.


Emergency Shutdown

Equipment will be turned down as fast as possible and depressurized and drained to ensure their safety in an emergency shutdown due to fire, large spills, or gas releases. Because of the shorter shutdown duration, emergency shutdowns can cause additional wear and tear on machinery.

In most cases, an emergency shutdown is required in the following situations:

  • Large-scale spills and gas leaks.
  • Shocking oil fire.

Shutdown Warnings

Advance notice must be given to the appropriate persons in the event of a shutdown that will disrupt downstream or upstream processes. Suppliers of utilities and feedstocks and downstream consumers fall under this category (s).

Approhire provides shutdown staff from the following countries:

UAE, Oman, Bahrain, Qatar, Kuwait, Saudi Arabia, CIS countries, Russia, Africa, etc., are only a few examples.

We keep an extensive pool of qualified candidates on hand for any vacancy that might arise throughout the shutdown process.

Candidate experience ranges from subzero temperatures in Russia to the Gulf of Mexico.