Project Controls and Estimation Curriculum

Turnaround

Module from the Project Controls and Estimation Curriculum curriculum.

Module 9 - Turnaround Cost and Schedule · Learning Objectives · 1. Break TA into Normal Work (planned), Scope Change (added), Emergent (found) · 2. Size mobilization (labor, scaffold, crane) for peak manloading · 3. Apply typical TA durations: 14-28 days for mid-unit; 35-45 days for FCC · 4. Benchmark TA cost: $5-15M for small unit, $50-200M for crude/FCC complete · 5. Track daily TA progress: open, earned hours, cost to date · Typical Turnaround Cost Breakdown

Category	% of TA Cost	Notes	Variable or Fixed	Peak Loading	Ref
Labor (direct)	40-55%	Welders, fitters, riggers	Variable	Peak mid-TA	AACE
Materials	15-25%	Gaskets, catalyst, spares	Fixed by scope	Mobilization	AACE
Equipment rental	5-12%	Cranes, scaffold	Fixed	Full TA	AACE
Scaffolding	5-15%	Setup + dismantle	Fixed	Peak construction	AACE
Catalyst	5-20%	HC + HDS + reformer	Fixed	Late TA	Vendor
Engineering + PM	8-12%	Planning + execution	Fixed	Pre + during	AACE
Contingency	10-20%	Emergent, growth	Fixed (%)	End	AACE 40R
Other indirects	3-8%	Utilities, insurance	Fixed	Full TA	Owner

Source: Project_Controls_Estimation_Curriculum_v1.xlsx · Sheet: Turnaround

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