Shutdown Checklist: Plant Shutdown Planning
A comprehensive checklist for planning and executing a plant shutdown. Covers pre-shutdown planning, execution, and post-shutdown commissioning.
Pre-Shutdown (4–8 weeks before)
☐ Define the shutdown scope — list all work to be done
☐ Create a detailed work order for each task
☐ Identify all required spare parts — check inventory and order
☐ Identify all required contractors — obtain quotes and book dates
☐ Create a shutdown schedule — Gantt chart showing task sequence and dependencies
☐ Identify critical path tasks — the longest sequence that determines the shutdown duration
☐ Coordinate with production — agree on shutdown date and duration
☐ Prepare permits — hot work, confined space, isolation permits pre-filled
☐ Prepare JSA/SWMS for each high-risk task
☐ Brief all personnel on the shutdown plan
☐ Arrange waste disposal — skips, chemical disposal, recycling
☐ Arrange temporary services — power, water, lighting, ventilation
Pre-Shutdown (1 week before)
☐ Confirm all spare parts have arrived and are correct
☐ Confirm contractor attendance and site induction
☐ Verify all tools and equipment are available (cranes, welding machines, etc.)
☐ Review the shutdown schedule with all team leaders
☐ Prepare the shutdown control room / meeting area
☐ Distribute the shutdown organisation chart with contact numbers
☐ Verify emergency procedures — first aid, rescue, evacuation
☐ Confirm waste disposal arrangements
☐ Hold a pre-shutdown safety meeting with all participants
Shutdown Execution
☐ Conduct daily safety briefing (toolbox talk) — review the day's tasks and hazards
☐ Isolate all equipment — LOTO verified by authorised person
☐ Verify zero energy before any work begins
☐ Execute work in sequence per the shutdown schedule
☐ Hold daily progress meetings — review completed work, plan next day
☐ Track progress against the critical path — flag delays immediately
☐ Inspect completed work — quality verification before handover
☐ Update the shutdown schedule — mark completed tasks, adjust remaining
☐ Manage changes — if scope changes, assess safety impact and update plan
☐ Record all work performed — update work orders with actual time and parts
Commissioning (Post-Shutdown)
☐ All work completed and inspected — punch list items resolved
☐ All tools, scaffolding, and temporary equipment removed
☐ All guards and safety devices reinstalled
☐ All isolation removed — locks and tags removed by each worker
☐ Area cleaned — housekeeping verified
☐ Pressure test completed (if required) — hydrostatic test passed
☐ Leak test — check all flanges, valves, and connections
☐ Instrument calibration verified — all sensors reading correctly
☐ Sequential startup — bring equipment online in the correct order
☐ Performance test — verify equipment meets design performance
☐ Monitor for 24 hours — watch for leaks, vibration, abnormal readings
☐ Shutdown debrief — what went well, what didn't, lessons learned
☐ Close all work orders and file documentation
Critical Success Factors
- Planning — 80% of shutdown success is in the planning phase. Start 4–8 weeks early.
- Scope control — don't add work after the plan is set. New scope creates delays.
- Spare parts — verify all parts are on-site and correct BEFORE starting. Missing parts cause the biggest delays.
- Daily communication — hold a daily progress meeting with all team leaders.
- Safety — don't compromise safety for speed. A lost-time injury extends the shutdown far more than taking time to do it safely.
- Lessons learned — hold a debrief after every shutdown and implement improvements next time.