AI-Driven Turnaround Planning
iPlanAI enables rapid turnaround planning - reducing what took months & years down to days or weeks. iPlanAI generates structured job plans from work descriptions, drawings, photos, and engineering documentation. Outputs include sequential job steps, trade allocations, crew sizes, manhour estimates, duration forecasts, materials, cost modelling, and confidence scoring. Planners retain full control — editing, regenerating, or refining AI outputs as required.
Increase tool time & standardise estimation
Every shutdown generates operational knowledge — but most organisations fail to capture and reuse it. Our turnaround planning software enables the use of industry norms and builds structured libraries of work packs, job steps, materials, and execution performance that can be redeployed across future events to ensure that all personnel involved in your STO are estimating planned effort, for common activity types, using the same effort estimation basis.
Outcome: Up to 89% reduction in repeat planning effort and significantly improved scope predictability.
Market standard STO workflow
User interfaces, data structures, and workflows reflect how shutdowns are planned and executed — enabling rapid software adoption with minimal training overhead. The platform is structured around real shutdown workflows available out of the box; however, it can also be configured to align with your existing STO process.
Risk‑Driven Scope Governance
iPlanSTO consolidates scope candidates from ERP notifications, inspections, reliability programmes, and operational requests into one governed environment, allowing you and your senior leaders, to sit together and have a focal point to determine your Turnarounds worklist consistently & efficiently.
Structured Risk Modelling and Economic Justification Tools
The Risk Assessment capability provides a structured, auditable method to evaluate and prioritise turnaround scope items. It combines likelihood, consequence, and economic value to ensure the final work list is optimised for safety, reliability, and production effectiveness.
The J-Factor measures whether the cost of executing work is justified by the reduction in business risk achieved. J-Factor thresholds guide scope decisions, while mandatory safety or regulatory work is always included regardless of value.
One Platform across the Entire STO Lifecycle
Shutdown performance is determined by how effectively planning, scope, materials, contractors, and execution teams operate as one. iPlanSTO connects every STO phase into a governed, connected Turnaround. Our turnaround planning software has been designed with the end user in mind; iPlanSTO is currently deployed across the globe and utilised by a diverse range of users.
AI Scoping tools
AI Scoping tools further enhance your decision quality through duplicate detection, risk coaching, and scope recommendations. You will have never built a better Turnaround work list in the past. iPlanSTO streamlines peer reviews and approvals for work order estimates and bills of materials.
Outcome: Lean, risk‑optimised shutdown scope aligned to operational priorities, that prevents you spending money planning work packs you later descope.
Materials & Contractor Services Intelligence
Execution success depends on material and contractor readiness. iPlanSTO integrates materials planning directly into job design — linking BOM data, consumables, spares, tools, and external services to each work order. Capabilities include Turnaround wide bill of materials, instant part counts for all components, procurement tracking, cost modelling, and external contractor progress monitoring.
Outcome: Execution‑ready work packs that prevent delays, shortages, and commercial disputes.
QA/QC & Completions Management
Digitise quality assurance, inspection, and system handover workflows within a structured completions environment. iPlanSTO captures all inspection activities, test results, punch items, and non-conformance records directly against work scopes and asset systems — creating a live view of technical assurance readiness. Assurance data is progressively compiled throughout execution — eliminating end-of-shutdown collation delays.
Outcome: Accelerated mechanical completion, improved handover confidence, and faster plant start-up through real-time assurance visibility.
Execution Tracking & Productivity Intelligence
Monitor shutdown performance as work happens — not after it finishes! iPlanSTO provides real-time execution visibility across labour, contractors, vendors, and emergent scope — enabling leadership teams to manage shutdown delivery dynamically rather than retrospectively. Progress is captured at job step / P6 activity level, providing granular insight into workface status, workforce deployment, and productivity performance. Field and office teams operate from a shared execution dataset — ensuring decisions are made using live operational intelligence.
Outcome: Greater shutdown control, improved workforce utilisation, and more predictable delivery outcomes.
Lessons Learned & Equipment History
Every shutdown provides operational insight — but without structured capture, that knowledge is lost. iPlanSTO records execution learnings, equipment performance observations, and maintenance improvement opportunities as part of the close-out process. These learnings are linked back to asset history and planning libraries — ensuring future shutdowns benefit from past execution experience.
Outcome: Continuous shutdown performance improvement and stronger long-term asset reliability.
Connected Shutdown Data Ecosystem
iPlanSTO integrates bi‑directionally with ERP, EAM, and enterprise scheduling platforms — ensuring shutdown data flows seamlessly across systems. Integrations include SAP, Maximo, IFS, Primavera P6, MS Project, and other enterprise platforms. Planning data — including resources, logic links, durations, and constraints — can be generated automatically and exported directly into scheduling environments.
Advanced Analytics & Reporting
Transform shutdown data into actionable performance intelligence. Configurable dashboards provide real-time insight across planning, execution, and assurance phases — enabling leadership teams to monitor performance dynamically. Integration with Power BI and enterprise reporting platforms enables organisations to embed STO performance into broader operational analytics frameworks.
Outcome: Data-driven shutdown governance and evidence-based decision making.
Joint Integrity & Flange Management
Maintain full lifecycle visibility of joints and flanged connections across shutdown execution. iPlanSTO provides a permanent digital register of flange assemblies — capturing component specifications, gasket materials, bolt torque settings, inspection records, and assembly history — all linked directly to work scopes and asset hierarchy. Joint records can be embedded within work packs and isolation plans, ensuring technicians execute assembly and reinstatement activities using verified specifications and approved procedures.
Outcome: Improved containment assurance, faster QA closeout, and reduced post-shutdown integrity failures.
Configurability
iPlanSTO offers a high degree of out-of-the-box configurability to suit your specific requirements. Key users are empowered, following initial training to refine the software to reflect their ongoing needs and processes without relying on third-party support. This enables users to operate in a much more agile way and avoid any potential delays.
Un-Planned Outage Management
iPlanSTO gives your team a proven playbook when time is against you — helping plants get online faster after unplanned downtime without cutting corners. In the event of an unplanned outage, iPlanSTO helps you quickly mobilise resources and minimise downtime.
Isolation & Energy Control Management
Plan, visualise, and govern isolations and blinds across mechanical, electrical, instrument, and process systems within a single controlled environment. iPlanSTO enables shutdown teams to design and manage full energy isolation strategies — incorporating valve isolations, electrical lockouts, instrument isolations, line breaks, and process containment requirements — all aligned to specific work scopes and asset locations. Isolation plans are digitally structured and embedded within work packs, ensuring field teams have clear, approved access conditions before execution begins.
Outcome: Safer shutdown execution, improved compliance traceability, and reduced delay caused by isolation conflicts or rework.
In-Built Scheduling
iPlanSTO includes a fully integrated scheduling environment designed specifically for Shutdown, Turnaround & Outage execution — eliminating reliance on disconnected planning tools for day-to-day event control. The in-built scheduling engine enables planners and execution leads to visualise, sequence, and optimise work orders directly within the STO delivery platform using an interactive Gantt interface.
Gantt Execution Control
Unlike static scheduling tools, iPlanSTO allows authorised users to commit schedule adjustments directly through the Gantt view — automatically updating linked work orders, labour allocations, and progress records in real time. This ensures that schedule changes are not isolated planning exercises, but fully integrated operational updates reflected across execution data. Dynamic shutdown scheduling — not static planning — improving execution agility, schedule confidence, and leadership decision visibility. Core API & Enterprise Integration Framework
Core API Capability Coverage
iPlanSTO is built on an open integration architecture designed to operate seamlessly within enterprise maintenance and operational technology ecosystems. Through a suite of exposed core APIs, organisations can exchange shutdown data securely and in real time — ensuring STO planning and execution remains fully aligned with ERP, EAM, materials, and asset systems. Core integration services include master data synchronisation, work management exchange, materials alignment, and status governance workflows. iPlanSTO ensures that execution and ERP records remain aligned.
User & Organisational Enablement
Enable full Turnaround collaboration within one governed platform. iPlanSTO supports unlimited users — including maintenance contractors, vendors, and specialist service providers — all operating within a shared turnaround dataset. This ensures all stakeholders work from the same scope, plans, materials, and execution status without requiring expansion of ERP user licences or granting contractors direct access to systems such as SAP.
Outcome:Improved cross-organisation communication, reduced data duplication, and fully aligned shutdown execution teams operating within a controlled digital environment.
Enhanced Governance Frameworks
Embed structured shutdown governance into every phase of STO delivery. iPlanSTO enforces a proven, stage-gated methodology that governs how scope is introduced, challenged, approved, planned, executed, and assured — ensuring shutdown performance is controlled, auditable, and repeatable. All governance actions are electronically recorded — creating a permanent audit trail of decisions, approvals, revisions, and accountability.
Outcome: Shutdowns delivered under controlled methodology — not informal coordination — improving predictability, compliance, and operational assurance.
Digital Work Pack Engineering & AI Review
Generate structured work packs embedding labour steps, materials, isolations, permits, drawings, photos, line walk certificates, location details, and QA requirements. Each work pack is digitally engineered to ensure execution readiness before shutdown mobilisation begins. Before packs are released to the field, iPlanAI validates whether the planned execution strategy is optimised — not just documented! AI-driven work pack assurance does not just improve planning quality — it directly protects shutdown revenue exposure at enterprise scale.
Designed for Turnaround Practitioners
iPlanSTO is engineered specifically for STO delivery — not adapted from generic maintenance or project software. The platform is structured around real shutdown workflows and is used by: Planners and schedulers, Mechanical, electrical, and instrument engineers, Supervisors and execution leads, Inspectors and QA/QC teams, Procurement and materials coordinators, Contractors and service providers, Turnaround and outage managers.
Monte Carlo Risk Analysis
The Monte Carlo Risk Simulator provides a probabilistic view of turnaround workload uncertainty using three-point duration estimates (best, most-likely, worst). The simulator calculates P10, P50, and P90 outcomes, the probability of meeting budget targets, and the contingency required to achieve confidence levels.
Monte Carlo Simulation with detailed planning data
Monte Carlo modelling simulates thousands of shutdown delivery scenarios again, but instead of using the three‑point estimates from Scope Management meetings, you feed the detailed planning of labour steps.
Outcome: Leadership teams gain confidence curves for schedule completion and budget exposure before execution begins.
Event Initiation
Allows for a holistic approach to be taken for all planned events ensuring availability of all required resources across your entire portfolio
