Learning Center

A Shift in Turnaround Strategy: Building a New Standard

Date: 01/28/25 | Author: AMACS Process Tower Internals | Category: Turnarounds |

In the demanding world of process plant operations, turnarounds present significant challenges that require precision, strategy, and teamwork. Despite their critical importance, studies show that the majority of turnarounds—up to 85%—fail to meet their objectives due to poor collaboration between owner teams and contractors. Overcoming these failures calls for a fundamental shift in approach, embracing a modernized paradigm that rethinks leadership structures and contractor engagement strategies.

Identifying Key Challenges

Turnarounds are inherently complex, often beginning with an incomplete understanding of the project’s scope. This unpredictability highlights the need for robust scope management systems that can accommodate evolving schedules. Yet, traditional approaches to turnaround management frequently fail to provide the flexibility required to adjust baseline schedules in response to scope changes. The resulting disconnect between planning and execution often leads to delays, cost overruns, and a sense of failure.

Other common turnaround issues include:

  • Relying on outdated methods simply because they’ve “always been done that way.”
  • Inadequate planning and preparation across critical aspects of the project.
  • An “us vs. them” mentality between in-house teams and contractors.
  • Misaligned financial and duration benchmarks that no longer reflect industry realities.
  • A lack of trust between management and contractors, undermining collaboration.

Additionally, industry restructuring has led to a noticeable decline in experienced personnel available for planning and executing turnarounds. Plants that prioritize short-term compromises over long-term expertise risk compounding these challenges. However, those that strategically integrate their core competencies with the skills of qualified contractors position themselves for success.

A Modernized Approach to Turnarounds

To move beyond past performance pitfalls, plants and engineering teams must adopt forward-thinking strategies. The following steps can help ensure a smoother and more successful turnaround process:

  1. Define a Clear Vision: Establish specific objectives and communicate measurable performance expectations to all stakeholders.
  2. Adopt Industry Best Practices: Continuously refine processes by researching and applying proven methods tailored to your facility’s unique needs.
  3. Anticipate Risks: Proactively identify potential challenges and opportunities to maximize success.
  4. Invest in Training: Strengthen the capabilities of your team through targeted training programs designed to enhance technical and managerial skills.
  5. Foster Collaboration: Build a unified team dynamic that leverages the strengths of both internal staff and external contractors.

Managing Human Resources Effectively

Turnaround success heavily depends on the effective management of skilled labor. Engineering and operations teams must:

  • Plan for Flexibility: Adjust staffing levels as tasks evolve, ensuring the right personnel are available for critical phases such as vessel inspections and blinding units.
  • Optimize Resource Utilization: Monitor labor deployment against schedule requirements to prevent delays or cost overruns while maintaining efficiency.
  • Secure Expertise: Partner with contractors who bring specialized skills to fill gaps and support time-sensitive tasks.

By maintaining a dynamic staffing strategy, turnaround managers can ensure critical work progresses on schedule while controlling costs.

Strengthening Communication

Clear and consistent communication remains a cornerstone of successful turnarounds. Field supervisors and management teams must prioritize cooperation over competition for labor resources, avoiding hoarding behaviors that can jeopardize project goals. Leaders should take direct responsibility for tracking progress and addressing bottlenecks, fostering accountability and alignment across teams.

Redefining Turnaround Processes

A forward-looking turnaround paradigm includes these essential elements:

  • Scope and Scheduling: Ensure alignment between scope, progress, and resource needs.
  • Safety Protocols: Integrate safety measures at every stage, from scheduling to permitting.
  • Management Oversight: Provide timely updates to executives and ensure alignment with project objectives.
  • Resource Planning: Monitor human and material resources continuously to meet evolving demands.
  • Inspection Coordination: Ensure inspectors have clear timelines and goals to avoid delays.
  • Contractor Collaboration: Select contractors with proven expertise in areas such as equipment maintenance and process optimization.

Other Considerations

Engineers in refineries and chemical plants play a pivotal role in ensuring turnaround success. Key engineering considerations include:

  • Equipment Upgrades: Evaluate opportunities for replacing aging components with advanced materials to improve reliability and performance.
  • Data-Driven Insights: Use historical performance metrics and predictive maintenance tools to guide decision-making.
  • Material Management: Ensure seamless coordination of materials and tools to prevent delays in critical workflows.
  • Process Optimization: Leverage cutting-edge technologies to enhance throughput and operational efficiency.

The Right Partners for Turnaround Success

Partnering with experienced contractors and suppliers can make all the difference during a turnaround. With over 40 years of expertise, AMACS delivers tailored solutions for process tower internals, replacement equipment, and advanced engineered products. Our team is available 24/7 to support your needs and ensure your turnaround meets its objectives.

Contact us today to discuss how we can help your refinery or chemical plant achieve efficient and effective results during your next turnaround.