Shutdown Management

Shutdown Management: turning Strategy into tactics

Planning and managing shutdowns, turnarounds and outages in the process plant environment is a complex and demanding function. They are high risk events due the high level of activity taking place in a compressed time frame and added to that the uncertainty associated with the work scope and all the other uncontrollable factors. It is therefore no surprise that more and more organisations are reviewing their shutdown and turnaround practices with the objective of improving.

Shutdown/turnaround costs comprise up to 30% or more of annual maintenance budgets and a delay in start-up can cause a loss of operating profit that exceeds the cost of the shutdown/turnaround. Planning and executing a turnaround event requires many people to be diverted and external resources to be contracted. They can be costly in terms of lost production, so a carefully designed plan can reduce costs. Minimizing the duration of the outage can have a major impact on reducing the cost of lost production. Augmentation of resources available to handle the planning and scheduling and then the execution and assisting in the start-up of the facilities will minimize the out-of-service time.


In this training seminar you will learn:

  • An holistic approach to shutdown and turnaround planning
  • The process, phases and stages of shutdown planning and execution
  • The elements and outcomes of each phase of the turnaround
  • How to identify and develop plans to reduce risks to quality, costs and schedule
  • How to plan and execute the start-up, close-out and compile the lessons learned

By the end of this training seminar, delegates will be able to:

  • Enhance the company’s turnaround management capabilities,
  • Apply a team approach in the planning and execution of turnarounds
  • Gain deeper understanding of the stages, phases, milestones, outcomes of the overall process
  • Apply improved and more integrated methods for planning and executing successful turnarounds
  • Apply new, proven techniques in turnaround planning and management
  • Develop an action plan to improve their own turnaround management techniques
  • Have a better understanding of their role in the process and the role of team members


Organisational Impact

The organisation will benefit from this training seminar by:

  • Improved motivation of employees that are now more confident about how to go about planning and managing their shutdowns and turnarounds
  • Improved shutdown work quality and less rework
  • Reduced shutdown durations due to the elimination of unnecessary work and proper scheduling
  • Reduced costs due to the smoothing of resource demand and improved resource utilisation
  • Fewer logistical delays due to improved planning and communication
  • Lower risk due to formal risk management


Personal Impact

The individual will benefit from this training seminar by:

  • A greater appreciation of the key role of planning in the shutdown process
  • Being able to analyse, compile and communicate the initial scope and estimates with confidence
  • A better understanding of how the shutdown/turnaround must support the current objectives of the organisation and plan accordingly
  • Being a able to recognise shortcomings in the current way of planning and scheduling and being able to actively contribute to improvement
  • Becoming a more valued member of the team due to improved knowledge in all aspects of shutdown and turnaround management
  • Improved self-esteem, confidence and a fresh outlook from exposure to quality training and also the opportunity to network with people from other organisations that face similar challenges



This online training course will utilize a variety of proven online learning techniques to ensure maximum understanding, comprehension, retention of the information presented. The training course is conducted Online via an Advanced Virtual Learning Platform in the comfort of any location of your choice.


Day one Day Two Day Three Day Four Day Five
Introduction to Shutdowns, Turnarounds and Outages (STO)

  • How STOs can contribute to the business
  • Critical success factors
  • The impact of STO strategy on return on investment
  • Justification of the scope and timing
  • Introduction to the STO life cycle phases
  • STO risk management
Pre-Planning and Preparation for Success

  • Communications and the role of stakeholders
  • Organization, roles and responsibilities
  • Preparation critical success factors
  • Programmed work scope identification and selection
  • Corrective work scope identification and prioritization
  • Risk-based scope of work
Planning for Safety, Quality and Efficiency


  • The critical outcomes of planning
  • The 5Ms of work quality
  • Work survey and analysis
  • Estimating
  • Hazards and contingency planning
  • The use of planning libraries
  • Work breakdown structure
Scheduling for On-Time Execution and Completion


  • Scheduling concepts, terms, and standards
  • Scheduling and resourcing trade-off techniques
  • Scope-based budgeting
  • Managing contracts and contractors
Staying in Control of Quality, Time, and Budget


  • Work packages and logistics
  • Quality planning and control
  • Execution and schedule control
  • Execution checkpoints
  • Commissioning and start-up
  • Administrative close-out, review and lessons learned