COURSE OVERVIEW:

Industrial shutdowns and turnarounds represent the most significant expenditure and risk profile for any capital-intensive facility. This course provides a high-level strategic framework for managing these complex events, where thousands of tasks must be synchronized within a narrow window of time. It focuses on the transition from traditional reactive approaches to a disciplined, milestone-driven methodology that ensures every turnaround is executed with precision, safety, and financial accountability.

The scope of this training covers the entire turnaround lifecycle, including long-term conceptual planning, detailed engineering, execution logistics, and post-turnaround evaluation. Participants will explore the critical interfaces between maintenance, operations, projects, and procurement to ensure a unified organizational focus. The curriculum emphasizes the importance of scope control and freeze dates to prevent the budget overruns and schedule slippage that frequently plague large-scale industrial outages.

Coverage includes advanced project management techniques such as Critical Path Method analysis, specialized resource leveling, and the integration of health, safety, and environmental protocols into the execution plan. The course also addresses the "human element" of turnarounds, focusing on leadership under pressure and the management of massive temporary workforces. By the end of this program, attendees will be equipped to deliver turnarounds that meet all technical requirements while adhering strictly to time and budgetary constraints.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Implement a structured Stage Gate process for shutdown and turnaround management.
• Establish a rigorous scope challenge process to eliminate non-essential work.
• Develop a comprehensive turnaround strategic plan aligned with business goals.
• Utilize advanced scheduling software to manage the critical path and float.
• Design a logistics and infrastructure plan to support large-scale onsite activities.
• Manage contractor selection and performance through specialized service level agreements.
• Conduct detailed risk assessments and develop robust mitigation strategies for outages.
• Establish a real-time progress tracking system to identify and correct delays.
• Optimize the procurement and kitting of long lead materials and specialized parts.
• Lead multidisciplinary teams through the high-pressure execution phase of a turnaround.
• Execute a seamless handover from maintenance back to operations for plant startup.
• Conduct post-turnaround audits to capture lessons learned and drive future improvement.

TARGET AUDIENCE:

This course is essential for Turnaround Managers, Shutdown Coordinators, Maintenance Managers, Plant Managers, Project Engineers, Schedulers, and Procurement Specialists involved in large-scale industrial outages.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.