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Factory Shutdowns: How to Manage Your Maintenance Operations Efficiently

11 September 2024

What is a factory shutdown?

A factory shutdown, also known as a plant shutdown, refers to the necessary process where all or part of production in an industrial plant is provisionally stopped.

This halt in production is used to carry out:

Maintenance operations

Inspections

Adjustments

Remedial work

Equipment upgrades

Factory Shutdowns require planning and organisation

Prior to a shutdown, there is a lot of planning involved to reduce manufacturing disruptions. For example, the planning phase identifies the scope of the process and what needs to be done. If objectives are not established, this can result in more disruptions to production and a significant financial loss. Scheduling and organising ensures a safe and efficient performance of maintenance operations.

The duration of a factory shutdown varies depending on the required maintenance and inspection actions. They are usually carried out when employees are on leave; this is typically around Christmas and New Year. Remedial works are carried out by the maintenance team.

Which sectors have factory shutdowns?

Oil and Gas

In the Oil and Gas industry, shutdowns are also referred to as turnarounds. The shutdown allows for vital tasks like inspection, maintenance, replacements and repairs. Turnarounds can last several weeks and involve important coordination.

Manufacturing

A manufacturing shutdown is planned for maintenance, repairs and upgrades. This allows the equipment to be inspected and optimise production lines. This may include routine inspections to a significant revamp.

Power and Utilities

A shutdown enables technicians to perform inspections across turbines, boilers, generators and electrical systems. This time allows necessary repairs and component replacements to occur.

Chemical Plants

The shutdown will be scheduled periodically for maintenance, upgrades, cleaning and repairs. The turnarounds are crucial for keeping the chemical plant running efficiently. Even though the plant is non-operational, this does not mean the facility is completely safe due to the chemicals, contamination, and hazardous substances involved in the processes.

Mining and Minerals

Mining operation shutdowns are planned based on the production cycles and equipment wear. During this period, equipment such as crushers, conveyors and mills will be inspected. Following this, repairs and maintenance will be conducted where necessary

Types of shutdowns

Planned Shutdown: This is a type of shutdown which is scheduled for industrial facilities. Facility shutdown management will plan this in advance, and the maintenance team will have a list of activities to carry out during the downtime.

Emergency Shutdown: This is when a facility must immediately stop operations. Typically, this is due to equipment failure. An emergency shutdown is often unplanned and can cause unscheduled downtime, which can impact production and increase cost to the company.

Partial Shutdown: This involves part of the facility continuing to operate, whilst other areas are shut down for maintenance. Partial shutdowns can be used alongside emergency shutdowns but may potentially cause additional issues for the start-up and product quality.

Full Shutdown: This is when the plant is completely stopped. Full shutdowns often co-inside with planned shutdowns, where preparations have been made with an actionable list for the maintenance team.

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What does a factory shutdown include?

You should consider the following before, during, and after a plant shutdown:

1. Plan the shutdown dates and assign the required resources and notify all relevant stakeholders about the planned shutdown.

2. Let the shutdown team know the budget for the maintenance operations.

3. Ensure your employees are safe and conduct an inspection of the equipment.

4. Ensure you are keeping a record of the maintenance tasks and remedial work and that they are up to date.

5. Carry out the maintenance operations and safely dispose of or store hazardous materials.

6. Guarantee the area is safe for employees to return and work.

Examples of remedial work required post-shutdown

After a shutdown inspection, various types of remedial work may be required to improve safety and efficiency of assets. The team of experts conducting the shutdown will provide recommendations based on what maintenance and repairs are required, across all essential assets and equipment.

Corrective repairs

If assets or equipment are damaged or not working efficiently, they will require repairs to fix the issues identified in the shutdown. For example, the facility management has noticed the boiler is not maintaining the desired temperature in areas of the premises. An inspection is carried out on the boiler to identify the issue, and the requested repairs are made to restore proper heating functionality.

Preventative maintenance

Maintenance refers to equipment that needs to be monitored regularly to ensure that it is working safely and efficiently. For example, electrical system inspections are carried out to check circuit breakers and system wide safety testing.

Replacements

If there is a malfunction or issue with the efficiency of a component, they will require a replacement. For example, if a lightbulb is not working, then a new lightbulb will be introduced.

Upgrades and modifications

In the planning part of the shutdown, upgrades and modifications may have been agreed upon to improve the efficiency of the equipment. Enhancements may also be recommended to the facility manager based on the inspection. This may make the equipment more economical. For example, a factory might upgrade to energy-efficient equipment to reduce operational costs.

Common equipment issues identified during a factory shutdown

Electrical failure

An electrical failure may occur when a circuit overloads or short circuits. This can lead to malfunctions of the equipment, production disruption or stopping the process altogether. A consequence of electrical failure can be electrical fires, injury to employees and costly repairs.

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Mechanical Failure

Mechanical failure may occur if preventive maintenance has not taken place or components of the machinery have broken down. This can cause the equipment to fail, which can lead to production stopping, or damage to other components. Misalignment or imbalances of machinery can cause excessive wear and tear to the components, which will result in reduced function. This can increase energy consumption and potential safety hazards.

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Contamination

Lubricants used across equipment may experience contamination if not stored correctly. If this occurs, assets may be subjected to increased friction or corrosion – which can result in total equipment failure. It is important to ensure any substances are stored to the regulatory standards to make sure there is safety on your premises.

Schedule your Oil Analysis

Plan your factory shutdown downtime

To ensure your shutdown period is executed effectively, you should plan your factory shutdown and make considerations for the pre-shutdown and post-shutdown processes. For example, which staff members are allocated for the maintenance tasks.

Planning and scheduling should consider the timings of the shutdown period, and when it is both necessary and appropriate to carry out the inspections, maintenance, repairs and upgrades to the facilities. The communication to the staff involved with the process is vital not only for the safety of those involved in the factory shutdown but also for the efficiency of the process.

Make sure to have a contingency plan for your plant shutdown; this might be needed if anyone is unable to fulfil their role due to illness.

Why are plant shutdowns vital to workplace safety?

Factory shutdowns are a vital component of asset management and plant maintenance.

For example, shutdowns are critical for:

Employee safety with the implementation of safer equipment.

Prevent equipment failure with regular inspection, maintenance and repairs.

Extend equipment lifespan with maintenance and upgrades to components.

Optimise performance by ensuring components and equipment are working properly and effectively.

Reduce unplanned downtime by complying with regulatory standards and legal requirements.

Overall shutdowns ensure factory and equipment reliability, quality of the product, and compliance with Health and Safety Executive (HSE) and other regulatory requirements are enhanced.

Planning for your next factory shutdown

At BES Group, we’re proud to deliver industry leading factory shutdown inspections, maintenance and repairs. Our team of accredited engineers provide flexible solutions for your commercial premises. We prioritise safety and compliance throughout every step of the process.

We cover a variety of areas such as Electrical Installation Condition Reports (EICR), Emergency Lighting Services, Asset Reliability, and Inspection Services.

Our key solutions include: