Understanding Turnaround & Shutdown Management.
Turnaround and shutdown management is critical in industries such as oil, gas, and manufacturing. These planned shutdown events—often referred to as TARs —temporarily halt operations to conduct essential maintenance, upgrades, inspections, and compliance checks.
A turnaround is more than routine maintenance—it's a strategic intervention in an asset’s lifecycle. The primary objective is to ensure the ongoing integrity and performance of installed equipment while minimising downtime, controlling costs, and ensuring safety and compliance.
Success in turnaround management requires meticulous planning, cross-functional coordination, and disciplined execution. When done right, TARs reduce unplanned downtime, enhance equipment reliability, and support safe and efficient operations post-event.
Why Effective Turnaround and Shutdown Management Matters
Major turnarounds and shutdowns are complex, high-cost undertakings that typically occur every 2 to 6 years, based on factors like equipment condition, inspection cycles, and operational goals. Poorly managed turnarounds can lead to production losses, safety incidents, and unplanned outages.
Key triggers for initiating a shutdown turnaround include:
- Declining asset performance or reliability
- Upcoming regulatory inspections or HSE requirements
- Identified opportunities for operational improvements
Given the scale and risk involved, effective shutdown turnaround management is essential for avoiding costly overruns and operational disruptions.
Building a Robust Turnaround Strategy
A successful turnaround begins with a dedicated team responsible for planning and execution. A best-practice approach to turnaround management includes:
- Clear definition and management of scope, schedule, and budget
- Development of detailed work packages
- Coordination of procurement and logistics
- Resource planning and scheduling
- QA/QC and safety (HSE) protocols
- Risk management and contingency planning
Embedding safety into every phase of the shutdown turnaround ensures not only compliance but also the protection of people, assets, and the environment.
Managing Shutdown Time and Cost with Precision
In shutdown turnaround management, time equals money. Each additional day of downtime can cost millions in lost revenue. Since many critical assets lack redundancy, effective scope control is essential—only truly necessary work should be included.
Strategies for cost and time optimisation include:
- Early preparation (ideally starting 18–24 months in advance)
- Pre-ordering long-lead materials
- Sequencing tasks for optimal workflow
- Enforcing strict scope control and change management
- Estimating at the work package level to avoid overengineering
Robust cost control and contingency planning help prevent budget blowouts. Digital tools like iPlanSTO from IAMTech enable teams to monitor progress and financials in real time, keeping projects on track and within budget.
iPlanSTO: Your Digital Turnaround Management Solution
iPlanSTO is a purpose-built shutdown turnaround management platform designed for the demanding needs of heavy industry. It supports every phase of a TAR—from initial planning to post-turnaround reviews.
Key features include:
- Integrated work scope and workpack management
- Advanced estimating and cost tracking
- Contractor and resource scheduling
- The ability to interface with existing systems
- Real-time progress updates and change control
With iPlanSTO, organisations gain a centralised, transparent, and data-driven approach to turnaround management, enabling safer, faster, and more cost-effective events.
What our Customers Say
Through IAMTech’s detailed understanding of our business, they develop products and solutions that deliver real, sustainable improvements. We consider them to be a strategic partner as opposed to just another service provider. Tony Jester - Executive Vice President, Altrad Services UK, Ireland and Nordics
Moving across to iPlan felt like a very hard decision when we were facing it but it has proved to be the right decision. Implementation was easier than we had feared and we are able to do things now which we had not dreamed of trying in the past. We have taken a giant leap forward, and it’s not just the planners working in isolation; everyone on site can pull together with common processes, share information, and work together as one team. I wouldn't dream of trying to deliver a shutdown without iPlan. Alex Curry, (Former Site Maintenance Services Manager, BP Saltend)
Final Thoughts
Turnarounds may be complex and high-risk, but they’re also powerful opportunities to enhance asset performance, reduce long-term costs, and improve operational resilience. With strong turnaround strategies and digital solutions like iPlanSTO, companies can take full control of their shutdowns and consistently exceed industry performance benchmarks.
Want to streamline your next shutdown turnaround? Get in touch with our team or book a demo of iPlanSTO today.
