🎯 Course Description:
This practical and intensive 5-day course provides participants with a structured approach to planning, executing, and closing out shutdowns and turnarounds (STOs) in process, power, oil & gas, and industrial facilities.
Participants will learn how to minimize downtime, manage costs, allocate resources effectively, and ensure safety and compliance throughout all phases of the shutdown lifecycle. The course integrates risk management, scheduling, contractor coordination, and post-turnaround analysis to ensure continuous improvement and long-term reliability.
👥 Who Should Attend:
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Maintenance and Shutdown Managers
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Turnaround Planners and Coordinators
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Project Engineers and Facility Managers
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Operations and Production Supervisors
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Procurement and Contracting Professionals
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HSE and Quality Assurance Officers
🗓️ Day 1: Shutdown and Turnaround Fundamentals
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | What is a Turnaround? – Definitions, drivers, and business impact |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Shutdown Lifecycle Overview – Phases from initiation to closeout |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Key Roles and Responsibilities – Stakeholders, planners, contractors |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Map the current STO process in participants’ organization |
🗓️ Day 2: Detailed Planning and Scope Development
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Scope Development – Defining, reviewing, and freezing the scope |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Risk-Based Work Selection (RBWS) – Prioritizing based on risk and value |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Work Breakdown Structure (WBS) – Planning hierarchy and deliverables |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Create a basic WBS and scope freeze matrix |
🗓️ Day 3: Scheduling, Budgeting, and Resource Allocation
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Developing the Turnaround Schedule – Logic, sequencing, critical path analysis |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Estimating and Budgeting Techniques – Labor, materials, contingencies |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Resource Planning – Internal teams, contractors, tools, logistics |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Build a simple turnaround schedule using Gantt or CPM format |
🗓️ Day 4: Execution, Monitoring, and Safety
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Execution Phase Management – Mobilization, daily coordination, and field control |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | HSE Considerations in Shutdowns – Permitting, confined space, LOTO, contractor safety |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Progress Tracking and Change Management – Earned value, delay recovery, scope creep |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Daily reporting format and shift turnover planning |
🗓️ Day 5: Closeout, Evaluation, and Continuous Improvement
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Mechanical Completion and Start-up – Verification, handover, punch lists |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Post-Turnaround Evaluation – KPIs, cost variance, lessons learned |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Continuous Improvement Strategy – STO benchmarking and future optimization |
| 03:00 – 03:15 | ☕ Coffee Break |
| 03:15 – 04:30 | Final Q&A, Feedback, Course Wrap-Up & Certificates |
📂 Course Materials Provided:
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Turnaround planning templates and checklists
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Sample WBS and scope development matrix
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Turnaround schedule and budget examples (Excel/Primavera)
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Risk-based work selection tool
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HSE compliance guide for STOs
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Daily execution report formats and shift plans
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KPI dashboard and post-turnaround review templates
