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Case Study:
Turnaround Controls Kept a $50M Upgrade on Track
A major refinery executed a 30-day, $50M upgrade under turnaround conditions. When unexpected corrosion threatened delay and cost, CMS applied EVM and CPM to re-sequence work, add a night shift, and keep stakeholders aligned.
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Completed in 32 Days
Only two days over the original 30-day schedule despite a mid-project reactor corrosion issue.
3% Budget Overrun with $1.5M Losses Avoided
Final cost $51.5M (3% over). Refined schedule and cost controls minimized downtime, saving an estimated $1.5M in potential losses from extended shutdown.
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Corrosion Threatened Schedule and Budget Mid-Project
Midway through the turnaround, unexpected corrosion in a key reactor required additional repairs, creating a potential 5-day delay and $2M in overruns.
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Discover CMS’s Unique
Advantage in Capital Projects
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EVM + CPM Response
CMS used earned value management and critical path method analysis with real-time schedule updates to identify impacts and keep control.
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Re-Sequencing & Resources
Non-critical tasks were re-sequenced; a night shift enabled parallel work to mitigate delay risk.
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Controls, Funding & Communication
Daily progress tracking and risk register updates drove proactive resolution. CMS facilitated rapid change order approval for additional funding. Stakeholder communication maintained alignment.
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Turnaround Outcome
- Duration: 32 days (2 days over plan)
- ComCost: $51.5M (3% over original $50M)petition: 19 sites, 12 companies (including large competitors)
- $1.5M in potential losses avoided via minimized downtime
- Operations resumed with upgraded systems meeting all safety and performance standards
32 days
total duration
3%
budget overrun ($51.5M)
$1.5M
potential losses avoided