Major turnarounds at US refineries and chemical plants routinely cost $50-500 million, with many exceeding budget by 20-30%. Cost overruns typically stem from poor scope definition, schedule delays, and inefficient resource utilization. AI scheduling helps facilities control turnaround costs through better planning, optimized resource allocation, and real-time progress tracking. Leading facilities are achieving 15-20% cost reductions through AI-powered turnaround management.
Cost Drivers in Turnarounds
- Labor: 40-50% of total turnaround cost
- Materials: 30-35% including parts and consumables
- Equipment: Cranes, scaffolding, specialty tools
- Lost Production: Opportunity cost during shutdown
Scope Creep Control
Uncontrolled scope additions during execution are the biggest budget buster. AI scheduling tracks scope changes and their cost/schedule impact, enabling better decisions about what work to include or defer.
AI Cost Optimization
- Resource leveling to reduce peak labor
- Equipment and tool utilization optimization
- Scope impact analysis for change requests
- Real-time budget tracking and forecasting
- Vendor and contractor coordination
Best Practices
- Planning: Detailed scope definition 12+ months ahead
- Scheduling: Resource-loaded schedules with AI optimization
- Execution: Real-time tracking and replanning
- Review: Post-turnaround analysis for continuous improvement
Control Your Turnaround Costs
See how AI scheduling can deliver your next turnaround on budget.
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