Turnarounds in chemistry - a discipline with the highest risk
Every hour counts - literally. In the chemical industry, a standstill not only means production downtime, but also costs millions. So it's no wonder that turnarounds are among the most sensitive and stressful project phases.
And yet? Many of them still proceed as they did 20 years ago: manually, non-transparently, organized via Excel lists.
There is another way. Better.
1. time is money - and planning is the be-all and end-all
A typical turnaround: running systems to zero, hundreds of work steps, dozens of trades, safety approvals, material flows, permits - everything has to be right on the dot.
But this often happens:
❌ Delays due to missing parts
❌ Bottlenecks due to poorly coordinated shifts
❌ Safety concerns with last-minute changes
2. safety is non-negotiable - even under time pressure
Chemical plants are high-risk zones. Anyone who works here is working in potentially explosive areas, with hazardous substances and under extreme time pressure.
Safety management is not an add-on, but an integral part of the project plan:
✔️ Early digital risk assessments
✔️ Real-time monitoring with mobile devices
✔️ Automated alarm workflows in the event of deviations
Modern platforms such as COMAN help to identify safety risks before they become acute - while still keeping the pace high.
3. Coordination of partners - if you don't involve everyone, you lose time
A turnaround project without external partners? Hardly conceivable. Service providers, experts, suppliers - they all have to work together in a highly complex time frame.
The problem:
Different tools, fragmented communication, constantly updated plans, but no shared vision.
The solution:
👉 A central, digital platform on which everyone involved works together.
👉 Shared access to schedules, progress reports and technical documentation - in real time.
Result: fewer misunderstandings, faster decisions and more efficient processes.
4. digital twins: simulation instead of surprise
Do you want to know where things are going wrong - before they do? Then you need a digital twin.
Digital twins are a 1:1 virtual representation of your system. So you can:
🔍 Simulate maintenance steps
🧭 Visualize bottlenecks or risks
📊 Evaluate the effects of changes in advance
This not only saves time, but also protects you from making costly mistakes.
5. advanced work packaging (AWP): structure beats chaos
AWP is more than just a buzzword. It means: work packages instead of a jumble of tasks.
You define in advance what needs to be done, when, how and with what - including resources, personnel and tools. No more improvising on the construction site.
✅ More structure
✅ Less waiting time
✅ Clear responsibilities
AWP ensures flow instead of frustration - especially in the time pressure scenario of a turnaround.
6. material availability: just-in-time or just-in-trouble?
A missing sealing ring. The wrong pump. An unauthorized shipment. And suddenly everything comes to a standstill.
This is where just-in-time procurement (JIT) can help - but only if it is perfectly coordinated with your project plan.
Digital systems such as COMAN integrate suppliers directly into your project:
🕓 No premature delivery
📦 No unnecessary storage costs
📲 No nasty surprises
Conclusion: Investing in turnarounds means investing in tools
Turnarounds are the Champions League final of the chemical industry: everything has to be perfect. Without digital tools, this is almost impossible today.
With solutions like COMAN Software, you get:
🚀 Real-time overview
🔐 maximum safety
🤝 efficient team coordination
🧠 forward-looking planning with digital twins
📦 Resource-saving implementation through AWP & JIT
Act now - before the next standstill occurs
👉 Let us show you how COMAN can digitally master your next turnaround.
Book a free demo appointment or workshop with our experts now.
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