MAJOR SHUTDOWN REFURBISHMENTS, NEW PROCESSES & ACQUISITIONS
Planning, Executing, and Controlling Complex Industrial Turnarounds and Upgrades
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 20 – 24 Jul 2026 | Dubai, UAE | USD 3495 per delegate |
Course Introduction
Major plant shutdowns, refurbishments, and process acquisitions are among the most complex and capital-intensive activities in industrial operations. Executing these projects requires precise planning, stakeholder coordination, risk control, and cost management to avoid delays, cost overruns, and safety incidents.
This course equips participants with a complete roadmap to manage planned shutdowns and integrate new processes or equipment during refurbishments and acquisitions. It focuses on technical preparation, contractor management, safety assurance, execution monitoring, and post-shutdown performance improvement.
Course Objectives
By the end of this course, participants will be able to:
• Plan and schedule shutdowns for minimal downtime and disruption
• Assess refurbishment scopes, specifications, and integration risks
• Coordinate multidisciplinary teams, vendors, and contractors effectively
• Implement safety and quality assurance throughout shutdown phases
• Evaluate post-shutdown performance and lessons learned
Key Benefits of Attending
• Gain end-to-end knowledge on planning and controlling shutdown projects
• Optimize execution windows to reduce lost production
• Enhance safety, compliance, and operational reliability
• Successfully integrate new processes or acquisitions during turnarounds
• Avoid the most common failure points in large industrial shutdowns
Intended Audience
This program is designed for:
• Plant Managers and Shutdown Coordinators
• Maintenance and Reliability Engineers
• Project Engineers and Turnaround Planners
• Operations and Technical Services Managers
• Procurement, HSE, and Contracting Professionals
Individual Benefits
Key competencies that will be developed include:
• Shutdown strategy development and critical path scheduling
• Scope definition, asset condition assessment, and execution control
• Integration planning for new equipment and processes
• Contractor and stakeholder coordination
• Post-turnaround analysis and performance improvement
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Reduced downtime and shutdown-related production loss
• Improved capital planning for refurbishments and asset upgrades
• Efficient execution of shutdown and startup procedures
• Enhanced asset reliability and lifecycle performance
• Higher return on investment in acquisitions and refurbishments
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – Shutdown frameworks, execution phases, risk control
• Case Studies – Lessons learned from large-scale shutdowns and upgrades
• Workshops – Develop shutdown plans, equipment integration strategies
• Peer Exchange – Share turnaround practices across industries
• Tools – Gantt charts, work packs, QA/QC templates, risk logs
Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Shutdown Planning and Pre-Execution Strategy
- Module 1: Objectives and Phases of Shutdown Projects (07:30 – 09:30)
• Refurbishment vs acquisition vs upgrade shutdowns - Module 2: Asset Evaluation and Scope Definition (09:45 – 11:15)
• Condition assessments, maintenance backlogs, critical equipment - Module 3: Shutdown Master Planning and Scheduling (11:30 – 01:00)
• Timelines, float, critical path, milestone tracking - Module 4: Workshop – Develop a High-Level Shutdown Schedule (02:00 – 03:30)
• Work breakdown structure and milestones
Day 2: Resourcing, Procurement, and Contractor Management
- Module 5: Work Pack Preparation and Task Sequencing (07:30 – 09:30)
• Priority ranking, modular planning - Module 6: Contractor Selection and Mobilization (09:45 – 11:15)
• Pre-qualification, contracting strategy, KPIs - Module 7: Shutdown Materials, Logistics, and Procurement (11:30 – 01:00)
• Lead time planning, storage, spare parts control - Module 8: Workshop – Contractor Scope and KPI Setup (02:00 – 03:30)
• Vendor planning checklist
Day 3: Safety, Quality, and Execution Monitoring
- Module 9: Safety Management during Turnarounds (07:30 – 09:30)
• Permit-to-work, confined space entry, LOTO - Module 10: Quality Control and Inspection Readiness (09:45 – 11:15)
• Test plans, documentation, QA/QC protocols - Module 11: Daily Execution Tracking and Control Tools (11:30 – 01:00)
• Dashboards, performance boards, punch lists - Module 12: Workshop – Create a Turnaround Safety Plan (02:00 – 03:30)
• Emergency readiness and control points
Day 4: Process Integration and Commissioning
- Module 13: Installing and Integrating New Equipment (07:30 – 09:30)
• Mechanical, electrical, automation alignments - Module 14: Commissioning and Start-Up Planning (09:45 – 11:15)
• Dry runs, checklists, team handover - Module 15: Managing Operational Risks Post-Refurbishment (11:30 – 01:00)
• Instrumentation, human error, test failures - Module 16: Workshop – Develop a Commissioning Matrix (02:00 – 03:30)
• System and subsystem readiness
Day 5: Performance Review and Lessons Learned
- Module 17: Post-Shutdown Review and Performance Analysis (07:30 – 09:30)
• Schedule compliance, scope creep, actuals vs planned - Module 18: Continuous Improvement and Documentation (09:45 – 11:15)
• Reporting, metrics, institutional learning - Module 19: Case Study – Turnaround Success and Failure Factors (11:30 – 01:00)
• Global shutdown projects: benchmarks and insights - Module 20: Final Workshop – Present a Refurbishment Execution Strategy (02:00 – 03:30)
• Group project and feedback session
Certification
Participants will receive a Certificate of Completion in Major Shutdown Refurbishments, New Processes & Acquisitions, validating their capability to plan, manage, and control major plant overhauls and technical upgrades with minimum risk and maximum performance impact.