Power & Energy · TurnaroundCompleted 2023

Refinery Turnaround Program

Every day offline costs a refinery dearly. This unit came back two days ahead of plan.

LocationGulf Coast

ClientConfidential

LocationGulf Coast

SectorPower & Energy

Value$260M

Size45-day outage

DeliveryEPC

Duration14 months

StatusCompleted 2023

Why it mattered

In energy, the schedule is a financial instrument. Interconnection dates, outage windows and tax-credit deadlines turn days into millions, and every hour offline has a price.

The challenge

A refinery planned a major turnaround with thousands of maintenance activities inside a forty-five-day window.

Each day offline meant lost production, so precision in planning paid for itself many times over. Scope discovered once equipment was opened had to be absorbed without breaking the window.

Our role

Shutdown & Turnaround Scheduling Progress Measurement Resource Loading Critical Path Analysis

Schedule at a glance

The whole program, on one line.

Start to finish, as the schedule tells it. For work still in progress, the bar moves with today's data date.

StartMay 2022

Duration14 months

HandoverJul 2023

Progress—

Plan to the hourProtect commercial datesMeasure progress objectivelyReturn to service

How we held the date

Our approach, phase by phase.

The same disciplined sequence we bring to every engagement, shaped around what this project needed most.

PHASE 01PHASE 02PHASE 03PHASE 04

PHASE 01Plan to the hour

Outages and turnarounds planned at hour level, with every craft and permit accounted for.

PHASE 02Protect commercial dates

Interconnection, tax-credit and offtake milestones held as hard dates.

PHASE 03Measure progress objectively

Quantity-based progress and earned value on every site, every period.

PHASE 04Return to service

Startup and testing sequenced to bring capacity on, or back on, by the committed date.

What changed

The difference we made

Measured the only way that matters: whether the date and the budget held.

Result 01Back on stream two days early

The unit returned to service forty-three days after shutdown, against a forty-five-day plan.

Result 02Updated every shift

Hour-level schedules coordinated every craft and were statused at each shift change, so discovered scope was placed within hours.

Result 03Safety never traded for time

Safety-critical activities kept their full durations; recovery came from sequence, not shortcuts.

Services engaged

What we brought to it

Our work in Power

2.01.14Shutdown & Turnaround Scheduling

Hour-by-hour shutdown and turnaround schedules that compress outage windows and return critical assets to service safely, on the date operations committed to.

2.02.06Progress Measurement

Quantity-based, field-verified progress measurement that turns physical work into numbers owners, lenders and auditors will accept.

2.01.10Resource Loading

Labor, equipment and cost loading that turns a schedule into a feasible plan for people, plant and cash, and the foundation for earned value.

2.01.07Critical Path Analysis

Rigorous analysis of critical and near-critical paths that shows leadership exactly where attention and money will move the date, and where they will not.

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