Why the Best Shutdowns are Won Before they Begin

In the oil and gas industry, shutdowns are among the most complex and mission-critical operations we ever undertake. They are high-stakes moments where engineering, logistics, safety and teamwork converge, and where success or failure can shape the performance and longevity of a facility for years to come.

At Serikandi Kent, we’ve just wrapped up the MLJ shutdown in Brunei. We managed this ahead of schedule, with additional scope successfully completed. The experience reaffirmed a belief I’ve held throughout my career: the secret to a flawless shutdown lies not in the final execution, but in the meticulous preparation that precedes it.

From the earliest planning stages, aligning manpower is one of the most important steps. Every tie-in, whether piping or electrical and instrumentation, needs the right people assigned, not just in terms of numbers, but in terms of skill, training and competency. That includes building in night-shift capability and allowing a buffer for unexpected absences. When the right individuals are in the right roles, the work flows smoothly and safely from the outset.

Procurement is another cornerstone of success. Reliable machinery, properly specified equipment and trusted subcontractors must all be secured well ahead of the shutdown window. This isn’t about ticking boxes. It’s about ensuring that when the time comes, everything you need is on site, operational and ready to perform without compromise.

Vendor engagement is equally critical. The support of specialist service providers, from scaffolding and pressurised habitat crews to PWHT, radiography, cold-cutting, flange management, torquing, flushing and cleaning, lifting and rigging, often determines how smoothly a shutdown proceeds. These partners need time to mobilise and plan, so early communication and collaboration are essential.

Leadership clarity underpins everything. Each tie-in should have a dedicated foreman and supervisor while the site itself remains under the control of a construction site manager. Clear lines of authority allow decisions to be made quickly and keep the operation agile in the face of evolving conditions.

Comprehensive documentation is another hallmark of an effective shutdown. Work packs and job cards must be prepared well in advance and shared with both the client and operations teams. Everyone involved should understand not just what work will be done, but how it will be sequenced, who will perform it and what resources will be deployed. PTW (Permit To Work) development is a collaborative effort between the Construction leads, HSE and PTW coordinator, each Tie-in permit folder should contain the relevant JSEA, Heavy Machinery and Equipment inspections, Approved latest revision isometric drawings and step by step execution procedures. By holding coordination meetings months before the shutdown begins, we can capture every activity accurately and reduce the risk of late-stage surprises.

Safety, of course, is the cornerstone and common thread that runs through every decision we ever make. Our HSE team plays a pivotal role safeguarding not just the shutdown activities, but the entire project, ensuring Compliance and Policy, Risk Management, Inspections and Audits, Training and Education, Emergency preparedness, Communication and Record keeping are upheld. Once a carbon-free facility is handed over to us and Lock Out Tag Out (LOTO) protocols are in place and understood, the execution phase can commence. LOTO procedures are fundamental to preventing accidental restarts and controlling hazardous energy. These topics should feature prominently in every meeting and toolbox talk leading up to the shutdown.

Attention to logistical details pays dividends too. Well-stocked stores, especially when it comes to PPE and essential consumables, keep teams working efficiently. Involving the pre-commissioning and quality control teams early provides an additional layer of expertise and ensures that construction remains aligned with project requirements throughout.

Finally, the work doesn’t end when the last flange is tightened. Post-shutdown procedures, including safe start-ups, functional testing, thorough clean-ups, waste disposal, and complete documentation, are crucial to closing out the operation successfully. And a post-shutdown review, focused on lessons learned and opportunities for improvement, sets the stage for even better performance on future projects.

At Serikandi Kent, we view shutdowns as an opportunity to demonstrate our capability, our discipline, and our commitment to excellence. The MLJ project proved once again that with careful planning, strong collaboration, and an unwavering focus on safety and quality, even the most complex shutdowns can be delivered ahead of schedule and beyond expectation.

Because in the end, shutdown success isn’t about what happens in the final days — it’s about everything you do in the months before. Preparation isn’t just part of the job. It is the job.