Critical chain and risk analysis applied to high-risk industry maintenance: A case study

Abstract

In this case study, the Theory of Constraints and Risk Assessment are applied to the turnaround process of an IGCC (Integrated Gasification Combined Cycle) plant. Turnaround project has been analysed as it had always been implemented up to 2006, identifying any related problems and inconsistencies, and then to describe the reengineering of this process, assessing and emphasizing the changes involved and identifying further opportunities for improvement. The aim of the study is to develop a prioritization method for Work Packages, within the Critical Chain context, in order to minimize the risks related to accidents in the refinery plants. This study addresses the applicability and necessity of the risk analysis process to examine and evaluate the schedule and cost features of a turnaround project. A comparison between the performance obtained for the turnaround using classic project management techniques and results obtained using the new planning system showed that the proposed method allowed the company to maximize the quality and safety of work and to minimize the turnaround time and cost. We also found that while improvement is feasible for turnaround in certain areas, the development of a maintenance improvement strategy that appreciates the needs of different stakeholders (providers, manufacturing units, etc.) is indispensable. Turnaround improvement strategy relates to policy, anticipation of problems, responsiveness of people and monitoring outcomes.