Turnaround/Outage Manager – Valve Scope

The Turnaround/Outage Manager – Valve Scope is responsible for planning, executing, and closing all valve-related activities during scheduled plant outages or shutdowns. This includes managing the replacement, servicing, testing, and documentation of valves and associated mechanical systems. The role demands precise coordination, vendor oversight, and safety leadership under compressed timelines.

🔧 Key Responsibilities:

1. 📋 Scope Definition & Planning

• Define the valve work scope: inspection, repair, replacement, testing, and upgrades

• Conduct walkdowns and coordinate with reliability/inspection teams to finalize valve lists

• Develop detailed valve shutdown plans including manpower, isolation maps, tie-ins, and testing sequences

2. 🛠️ Execution Management

• Oversee all valve activities during the outage: removal, hydrotesting, machining, lapping, assembly, and calibration

• Manage specialized valve contractors, OEM reps, and site technicians

• Ensure all safety, permit, LOTO, and pressure testing protocols are enforced

3. 🧾 Documentation & QA/QC

• Maintain valve traceability records (serials, tests, photos, inspection reports)

• Review and approve FAT/SAT documentation, test certificates, and repair logs

• Ensure redlining of drawings and timely submission of as-built documentation

4. 🕒 Schedule & Resource Coordination

• Build and manage the valve execution schedule in alignment with overall turnaround timeline

• Forecast labor, tool, crane, rigging, and welding support needed for valve packages

• Interface with piping, I&C, scaffold, insulation, and HSE teams for interdisciplinary planning

5. 💬 Stakeholder Communication & Reporting

• Lead daily permit meetings, progress briefings, and readiness reviews for valve systems

• Report progress, critical path issues, and completion percentages to Turnaround Management

• Manage punch lists and turnover packages to Operations and QA

🎯 Key Focus Areas:

• ✅ Safe and timely execution of valve work within the outage window

• ✅ Zero leak-startup and compliance with pressure boundary integrity

• ✅ Valve contractor/vendor performance management

• ✅ Critical path control for large valve tie-ins or hydrotest loops

• ✅ Cost control of valve-related work packages

🧰 Tools & Systems:

• Software: Primavera P6, MS Project, SAP PM, Oracle EAM, CMMS platforms

• Databases: Valve registry systems, tag tracking sheets, test logs

• QA Tools: API/ASME inspection forms, hydro/pneumatic test sheets, torque logs

• Safety Systems: Permit-to-work, LOTO registers, confined space and hot work protocols

📊 Performance Metrics (KPIs):

• % of valves completed within shutdown schedule

• of valve-related startup leaks or failures

• % of valve packages with complete documentation

• of safety incidents (TRIR) related to valve work

• Cost variance on valve scope vs. estimate

• Contractor performance ratings (quality, safety, delivery)

👥 Team & Vendor Interface:

• Internal: Reliability Engineers, Maintenance, Operations, QA/QC, Safety

• External: Valve OEMs, field machining services, testing contractors, hydrotest vendors

• Direct Reports May Include: Valve supervisors, coordinators, planners, field engineers

🧠 Leadership & Competencies:

• Strong understanding of mechanical system integrity and pressure boundary controls

• Ability to manage under pressure in high-stakes turnaround environments

• Leadership in multi-disciplinary teams with 24/7 rotating work schedules

• Excellent coordination, problem-solving, and documentation skills

• Commitment to safety, quality, and reliability