Planning & Scheduling for Shurdown and Turnaround

Petrotech Academy, Mahabubnagar

Project Planning & Scheduling for Shutdown & Turnaround Projects

Using Oracle Primavera P6

Complete end-to-end course content and the role of the planning engineer in shutdowns and turnarounds, as per Saudi Aramco, SABIC, ADNOC and PDO standards and best practices: from strategy and scope to scheduling, risk, delay analysis and closeout.

15Course modules
11Steps in the end-to-end planning flow
Oracle Primavera P6Main tool
Hands-on exercisesBuild a turnaround schedule in P6

Course overview

About this course

A practical programme for planners and project controllers who prepare, schedule, monitor and close out shutdown and turnaround projects in Oil & Gas and Petrochemical plants. It follows the full turnaround planning lifecycle in Primavera P6, under client standards and best practices.

Planning engineer tools and skills

  • Primavera P6 (Advanced User)
  • Microsoft Excel (Advanced)
  • Power BI / Dashboards
  • Risk Analysis (Monte Carlo)
  • Delay Analysis Techniques
  • Earned Value Management
  • Data Analytics & Reporting
  • Communication & Coordination
  • Problem Solving & Decision Making

Course outcomes

  • Understand shutdown & turnaround planning lifecycle
  • Develop integrated & resource loaded schedules in P6
  • Apply industry standards & best practices
  • Monitor progress & control project performance
  • Perform risk & delay analysis
  • Generate management reports & dashboards
  • Enhance coordination & decision making
  • Add value as a professional planning engineer

Who should attend

  • Planning Engineers / Project Planners
  • Schedulers / Project Controllers
  • Construction Managers
  • Maintenance Managers
  • Project Managers
  • Cost Engineers
  • Anyone involved in shutdown & turnaround planning

End-to-end shutdown and turnaround planning process flow

The eleven steps every module in the course supports, from setting the strategy to the post-turnaround review.

  1. 1Strategy & Scope
  2. 2Work Identification
  3. 3WBS Development
  4. 4Activity Planning
  5. 5Resource Planning
  6. 6Duration Estimating
  7. 7Cost Loading
  8. 8Risk Analysis
  9. 9Schedule Baseline
  10. 10Execute & Monitor
  11. 11Review & Closeout

Complete end-to-end course content

Fifteen modules, each with the client standards and procedures it follows.

Foundations: Strategy, Scope and Work Identification

1

Introduction

  • Overview of Shutdown & Turnaround (S&T)
  • Types of Turnarounds (Minor, Major, Critical)
  • Objectives & Success Criteria
  • S&T Lifecycle & Key Phases
  • Challenges & Best Practices

Standards: Aramco, SABIC, ADNOC, PDO

2

Shutdown Strategy & Planning

  • Shutdown Strategy Development
  • Scope Definition & Objective Setting
  • Risk Assessment & Mitigation Planning
  • Shutdown Budgeting & Cost Control
  • Stakeholder Identification & Governance

Standards: SAEP-331, SAEP-14, SAEP-12, Aramco GI-02.710, GI-20.520, PDO PIMS

3

Scope Definition & Work Identification

  • Equipment Identification & Tagging
  • Work Identification (Inspection, Repair, Replace)
  • Work Packaging & Job Plan Development
  • Backlog Management
  • Scope Changes & Impact Assessment

Standards: Aramco EPM Manual, SABIC PEM, ADNOC PES, PDO PIMS

Building the Schedule: WBS, Activities, Durations, Resources and Calendars

4

Work Breakdown Structure (WBS)

  • Develop Turnaround Specific WBS
  • Levels of WBS (L1 to L5)
  • Align with Equipment & Systems
  • Integrate with Cost & Resources

Standards: SAEP-14, Aramco WBS Guide, SABIC WBS Standard, ADNOC WBS, PDO PIMS

5

Activity Planning & Sequencing

  • Activity Identification & Definition
  • Logical Relationships (FS, SS, FF, SF)
  • Lead / Lag & Constraints
  • Critical Activities Identification
  • Integration with Other Disciplines

Standards: SAEP-12, P6 Best Practices

6

Duration Estimating

  • Duration Estimating Techniques
  • Use of Historical Data
  • Productivity & Crew Productivity Rates
  • Factors Affecting Durations
  • Uncertainty & Contingency

Standards: Aramco Productivity Library, SABIC Rates, ADNOC Guidelines, PDO PIMS

7

Resource Planning

  • Resource Types (Labor, Equipment, Material)
  • Resource Loading in P6
  • Resource Calendars & Shifts
  • Crew Composition & Productivity
  • Resource Levelling & Smoothing

Standards: Aramco Manpower Standards, SABIC Resource Standards, ADNOC, PDO

8

Calendar Management

  • Global, Resource & Project Calendars
  • Shift Patterns (Days, Nights, Rotations)
  • Non-Working Days & Exceptions
  • Calendar Alignment with Site Conditions

Standards: Aramco Calendar Standard, SABIC, ADNOC, PDO

Cost, Progress, Risk and Delay

9

Cost Loading & Integration

  • Cost Codes & Cost Accounts
  • Cost Loading in P6
  • Budget at Completion (BAC)
  • Earned Value Management (EVM)
  • Cost Performance Monitoring

Standards: Aramco Cost & Scheduling Manual, SABIC PEM, ADNOC, PDO

10

Progress Measurement & Monitoring

  • Progress Measurement Systems (Weightage)
  • Physical Progress vs Plan
  • Daily, Weekly, Monthly Updates
  • Documenting Actuals in P6
  • KPIs: SPI, CPI, TCPI

Standards: Aramco PMS, SABIC, ADNOC, PDO PIMS

11

Risk Management & Schedule Risk Analysis

  • Risk Identification & Assessment
  • Qualitative & Quantitative Risk Analysis
  • Monte Carlo Simulation in P6
  • Risk Register & Mitigation Plans
  • What-If Scenario Analysis

Standards: SAEP-331, Aramco Risk Management Manual, SABIC, ADNOC, PDO

12

Delay Analysis

  • Delay Types (Excusable, Compensable)
  • Time Impact Analysis (TIA)
  • As-Planned vs As-Built
  • Windows Analysis
  • Collapsed As-Built

Standards: Aramco Claims Procedure, SAEP-331, SABIC, ADNOC, PDO

Reporting, Integrated Master Schedule and Closeout

13

Reporting & Communication

  • Standard Reports in P6
  • S-Curves, Histograms, Cash Flow
  • Look-Ahead Schedules (3W / 6W / 12W)
  • Executive Dashboards
  • Highlight Reports & Exception Reports

Standards: Aramco Reporting Standards, SABIC, ADNOC, PDO

14

Integrated Master Schedule (IMS)

  • Development of IMS in P6
  • Integration of All Disciplines
  • Level 1 to Level 5 Schedule Structure
  • Interface Management
  • Schedule Quality Checks (DCMA 14 Point)

Standards: SAEP-331, SAEP-14, Aramco IMS Requirements, SABIC, ADNOC, PDO

15

Closeout & Lessons Learned

  • Post-Turnaround Review
  • Performance Evaluation
  • Lessons Learned Documentation
  • Final Reports & Handover
  • Continuous Improvement

Standards: Aramco, SABIC, ADNOC, PDO Best Practices

Role of a planning engineer in shutdown and turnaround projects

Role of a planning engineer

  • Develop integrated turnaround schedule in P6
  • Define activities, logic, resources & durations
  • Ensure alignment with scope, budget & resources
  • Perform schedule risk & what-if analysis
  • Monitor progress & forecast completion
  • Identify constraints & propose solutions
  • Support planning of critical activities
  • Prepare look-ahead schedules
  • Maintain schedule baselines & revisions
  • Ensure compliance with client standards
  • Facilitate meetings & communicate updates
  • Support cost & resource optimization
  • Prepare delay analysis & recovery plans
  • Ensure data integrity in P6
  • Provide decision support to management

Key responsibilities

  • Develop & maintain integrated shutdown schedule
  • Perform schedule review & risk analysis
  • Ensure logic, resources & durations are accurate
  • Monitor daily progress & update schedule
  • Prepare recovery & re-sequencing plans
  • Track critical path & float consumption
  • Prepare dashboards & KPI reports
  • Support HSE, quality & compliance planning
  • Coordinate with all disciplines & contractors
  • Ensure data accuracy & quality in P6
  • Manage changes & maintain schedule integrity
  • Perform delay analysis (TIA, Windows, As-Built)
  • Support claims & extensions of time (EOT)
  • Provide management with decision support

Practical exercises and course features

Hands-on practical exercises

  • Create a shutdown project from scratch in P6
  • Develop WBS & activities for a turnaround
  • Assign relationships, leads / lags & constraints
  • Load resources & level the schedule
  • Create & manage calendars & shifts
  • Cost load the schedule & generate S-Curves
  • Update progress and measure performance
  • Perform what-if & risk analysis (Monte Carlo)
  • Conduct delay analysis (TIA & Windows)
  • Prepare reports, dashboards & look-ahead schedules

Course features

  • Industry aligned standards
  • Practical & hands on
  • Real time case studies
  • Templates & checklists
  • Expert tips & best practices
  • Career enhancement
  • EPC / EPCC focus

Client standards and documents covered

The same planning steps, applied under the requirements of each client.

Saudi Aramco

  • SAEP-331
  • SAEP-12
  • SAEP-14
  • SAEP-21
  • GI-02.710, GI-20.520
  • Cost & Scheduling Manual
  • EPM Manual
  • PMS Manual

SABIC

  • SABIC PEM (Project Execution Model)
  • SAES-H-006
  • Project Controls Manual

ADNOC

  • PES (Project Execution System)
  • Schedule & Cost Control Procedures

PDO

  • PIMS (Project Integrated Management System)
  • PDO-90 Cost Control
  • Project Controls Guidelines

Standards and references you will work with

Turnaround planning follows client procedures, supported by international good-practice standards, inspection codes that drive the scope, and Indian statutory requirements. The course teaches how to apply them together.

International standards and practices

PMI, AACE, DCMA, SCL, API, ISO
  • PMI PMBOK Guide / Practice Standard for SchedulingProject management and scheduling good practice
  • AACE RP 37R-06Schedule levels of detail for EPC projects
  • AACE RP 57R-09Integrated cost and schedule risk analysis using Monte Carlo simulation
  • AACE RP 29R-03 / RP 52R-06Forensic schedule analysis, prospective time impact analysis
  • ANSI / EIA-748Earned value management systems
  • DCMA 14-Point AssessmentSchedule quality checks
  • SCL Delay and Disruption ProtocolGuidance on delay analysis and claims
  • ISO 31000Risk management guidelines
  • ISO 21500 / ISO 21502Guidance on project management
  • API 510 / 570 / 653In-service inspection requirements that drive turnaround scope
  • ISO 45001 / ISO 9001Occupational health and safety, quality management

BIS and Indian references

Standards, statutes and safety bodies
  • IS 15883Construction project management guidelines
  • Factories Act, 1948Safe working, confined spaces and pressure plant during shutdowns
  • Indian Boiler Regulations (IBR)Statutory boiler inspection and certification windows
  • SMPV(U) Rules 2016 / PESOStatutory inspection of pressure vessels
  • OISD standardsOil Industry Safety Directorate guidelines, including work permit and shutdown safety
  • Contract Labour (Regulation and Abolition) Act, 1970Contractor manpower requirements for shutdown crews
  • Indian Contract Act, 1872Contracts, extension of time and damages

Client and industry procedures

Aramco, SABIC, ADNOC, PDO
  • Saudi AramcoSAEP scheduling, cost and project execution procedures
  • SABICProject Execution Model (PEM) and project controls manual
  • ADNOCProject Execution System (PES) and schedule and cost control procedures
  • PDOProject Integrated Management System (PIMS) and project controls guidelines
  • Client turnaround proceduresShutdown readiness, work scope freeze and permit requirements
  • Client and project specificationsAlways override and extend the general standards

The procedure and edition that apply depend on the contract and client. Participants are trained to confirm the governing document before preparing a schedule.

Course content at a glance

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Project Planning and Scheduling for Shutdown and Turnaround Projects using Oracle Primavera P6, complete course content and role of planning engineer

Add value as a professional turnaround planning engineer

Develop integrated, resource-loaded schedules in Primavera P6, control progress and risk, and support decisions from shutdown strategy to closeout.

Hands-on: build a shutdown schedule from scratch in Primavera P6.

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