Phase 1: Initialization

Where chaos is eliminated before it ever appears.

This phase is crucial in preventing: unclear objectives, scope creep by committee, last-minute "urgent additions", and silo conflicts between Operations, Maintenance, and Projects. To accomplish this, we aim for the following key deliverables: turnaround objectives & constraints, high-level milestone map, preliminary resource plan, initial risk register, and a documented operating model for the entire TAR lifecycle

Phase 2: Scope Definition & Freeze

Cutting Out the Noise.

Most shutdowns run long because the scope wasn’t truly controlled.
Our method uses a structured, evidence-based funnel instead of emotional decision-making.

How scope is built:

1. Collection of raw work lists
2. First-pass screening
3. Independent criticality analysis (mandatory / preventive / opportunistic)
4. Risk-of-not-doing assessment
5. Identification of work that can be done before or after the TAR
6. Full justification of every remaining item

What this achieves:

1. 20–40% reduction in shutdown duration
2. Lower cost without sacrificing reliability
3. A scope that reflects asset risks, not personal preferences
4. A mechanism to approve or reject late additions based on clear criteria

Final Output:

A frozen, defendable, and risk-balanced scope with a formal process for approving any exceptions.

Phase 3: Detailed Planning

Turning Preparation Into Architecture

This is where the method becomes unmistakably different from traditional “good intentions” planning.

Core Components

3.1 Integrated Schedule (“Oil-out to Oil-in”)

1. Shutdown plan
2. Execution plan
3. Startup readiness
4. Integration of investment projects and equipment replacements

3.2 Logical Work Structure

Breaking the unit into manageable blocks by:

1. Equipment type
2. Physical location
3. Operational zones
4. Utility dependencies

This creates clarity in responsibilities and eliminates overlap.

3.3 T-Sessions (TMP/TMPTM)

Workshops that challenge every duration, step, and assumption to uncover:

1. Theoretical maximum performance
2. Compression opportunities
3. Parallelization options
4. Improved sequences

3.4 Quality Control Architecture

1. Inspection checkpoints
2. Weld/NDT protocols
3. Pressure test sequencing
4. Acceptance criteria

3.5 Logistics & Infrastructure Planning

Everything that usually breaks a shutdown:

1. traffic flows
2. crane layouts
3. material staging
4. contractor facilities
5. waste routes

A fully engineered turnaround where each hour, each resource, and each interface is accounted for. No guesswork.
No “we’ll figure it out onsite.”

Phase 4: Execution

A Daily Machine, Not Daily Firefighting

When planning is done right, execution becomes predictable. But the method adds a second layer: daily operational discipline.

Execution practices

1. Structured daily leadership meetings
2. Critical-path protection routines
3. Field-verified progress (not office-only reporting)
4. On-the-spot decision loops
5. Contractor performance monitoring

Startup Readiness

Before the unit is handed back, the system performs a full Pre-Start-Up Safety and Integrity Review:

1. completion of all QC checks
2. updated P&IDs
3. commissioning documentation

Why this matters

Execution becomes:

1. stable
2. transparent
3. interruption-resistant
4. faster than legacy TAR processes

And the project team finally stops firefighting and starts managing.

Phase 5: Completion & Learning

Turning One Success Into the Next

A TAR is only truly successful if the lessons carry forward.

The method enforces:

1. structured Lessons Learned workshops
2. formal contractor performance evaluation
3. updated defect lists for the next shutdown
4. documentation and archiving according to standards

Why it matters

This phase creates compounding improvement.
The next shutdown is always better than the last — faster, safer, cheaper, cleaner.