Shutdown projects look simple on a schedule: one week to stop, remove, install, qualify, and hand the system back to production. In reality, there is almost no margin for surprises.

In this project, a multi-phase shutdown and revamp had to be executed across several campaigns. Production would stop one system for a fixed window, we would complete the revamp and qualification, and then hand it back online before the next batch. The shutdown dates were fixed and non-negotiable.

On paper, the Basis of Design seemed sufficient to start. Once we moved into detailed 3D design, the real picture emerged: the BOD was outdated, several points were undefined, and the number of elements and components was significantly higher than originally planned. More valves, more instruments, more supports, more tie-ins – and with that, more welding, more installation, and more qualification work on site. What could not change was the shutdown window.

Since extending the schedule was not an option, we changed the way we worked. We increased manpower both on- and off-site, with a strong focus on 3D design and coordination. We prefabricated as many modules and pipe spools as possible off-site, so that shutdown time was used for installation and connection rather than improvisation. On site, we structured the teams to execute in parallel across multiple systems, instead of working in a single linear sequence.

Scope continued to evolve as details were clarified, but each change was handled transparently: impact assessed, options discussed, decisions documented.

The result? A larger and better-defined scope delivered within the original shutdown windows – and the client’s production back online as planned.

This is how we work: prepared, parallel and documented. When the scope grows and the shutdown window does not move, the outcome is decided in the preparation. Every change of scope is assessed, agreed and recorded before it goes into execution.

• Shutdown revamp with fixed, non-negotiable deadlines
• High-level Basis of Design with several open points
• Detail design reveals significantly more elements and components
• Siteworks (welding, assembly, qualification) far beyond original scope

• Increased manpower on- and off-site, especially in 3D design
• Parallel installation across multiple systems during shutdown
• Maximum prefabrication of modules and assemblies off-site
• Agile and transparent handling of scope changes and adjustments

When scope grows but the shutdown window doesn’t, preparation and parallelism are everything.