Shutdown/Turnaround Checklist
Maximize uptime & minimize risk with our comprehensive Manufacturing Shutdown/Turnaround Checklist! Ensure safety, efficiency, and compliance during plant shutdowns. Downloadable & customizable for optimal results.
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Planning & Preparation
Activities related to planning, risk assessment, permit acquisition, and communication prior to the shutdown.
Planned Shutdown Start Date
Planned Shutdown End Date
Estimated Shutdown Duration (Days)
Shutdown Scope Description
Affected Areas/Units
Shutdown Type
Risk Assessment Document
Permit Required (Yes/No)
Personnel & Safety
Ensuring adequate staffing, safety protocols, and emergency preparedness for the shutdown.
Number of Personnel Involved
PPE Requirements (Select all that apply)
Briefing/Toolbox Talk Topics Covered
Date of Safety Briefing
Time of Safety Briefing
Emergency Contact Person(s)
Emergency Procedures Reviewed (Fire, Medical, Spill)
Attach Relevant Safety Documentation (SDS, Permit to Work)
Safety Supervisor Sign-off
Utilities & Services
Steps required to isolate, depressurize, and secure utilities like electricity, water, steam, and compressed air.
Main Power Supply Voltage (V)
Steam Supply Isolation Method
Detailed Notes on Steam Isolation Procedure
Scheduled Time for Water Supply Isolation
Compressed Air Line Isolation
Description of Partial Compressed Air Isolation
Date of Last Utility System Inspection
Water Tank Level (%), prior to shutdown
Nitrogen Purge Required?
Equipment Isolation & Lockout/Tagout (LOTO)
Procedures for isolating and securing equipment to prevent accidental startup.
Select Isolation Method
Describe Isolation Procedures
Lock Number (if applicable)
Energy Source
Affected Equipment (Check all that apply)
Isolation Verification Signature
Isolation Verification Date
Isolation Verification Time
Mechanical Work
Tasks related to mechanical repairs, replacements, and inspections.
Describe the specific mechanical work to be performed.
Estimated labor hours required for mechanical work.
Upload detailed mechanical work scope documents/drawings.
Type of Mechanical Repair (e.g., replacement, overhaul, inspection).
Estimated Start Date for Mechanical Work.
Estimated Start Time for Mechanical Work.
Specialized tools or equipment required.
Part Number(s) of replaced components.
Mechanical Work Completion Signature
Electrical Work
Activities involving electrical equipment, including testing, repairs, and upgrades.
Voltage Readings - Phase A
Voltage Readings - Phase B
Voltage Readings - Phase C
Insulation Resistance Test Result (Megger)
Detailed Observations During Insulation Resistance Testing
Electrical Safety Checks Performed
Date of Next Electrical Inspection
Upload Infrared Thermography Report (if applicable)
Equipment Tag Number for Disconnect Switches
Electrician Sign-off
Instrumentation & Control Systems
Tasks related to calibration, testing, and maintenance of instrumentation and control systems.
Calibrate Flow Meter - Loop X
PLC Program Backup Status
Record any observed deviations during calibration
Last Calibration Date - Controller Y
Time of Calibration - Controller Y
Upload Calibration Certificates
HMI Screen Functionality Test Result
Loop Checks Performed
Process & Cleaning
Steps for cleaning, flushing, and preparing process equipment for maintenance or inspection.
Describe the cleaning procedure to be followed. Include any specific chemicals or techniques.
Target cleanliness level (e.g., % reduction in contaminants)
Cleaning Method Selected
Upload SDS (Safety Data Sheets) for cleaning chemicals.
Date of Last Cleaning
Record any unusual observations or issues encountered during cleaning.
Waste Disposal Method
Estimated Cleaning Duration
Post-Shutdown Activities & Restart
Procedures for post-maintenance checks, system re-integration, and controlled equipment restart.
Planned Restart Date/Time
Actual Restart Time
Pressure Readings (Confirm within spec)
Temperature Readings (Confirm within spec)
Checklist Verification - Restart Sequence Complete?
Confirm Safety Interlocks Functioning Correctly
Any Issues Encountered During Restart?
Restart Verification Signature
Production Levels Restored?
Notes on initial production run
Documentation & Sign-off
Ensuring all work is properly documented, signed off, and lessons learned are captured.
Shutdown Start Date
Shutdown End Date (Planned)
Planned Restart Time
Summary of Work Performed
Total Shutdown Duration (Hours)
Deviations from Planned Shutdown (Check all that apply)
Details of Deviations (if any)
Supporting Documentation (e.g., Inspection Reports, Photos)
Shutdown Supervisor Sign-off
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