Planning for Quality in Shutdowns & Turnarounds
Shutdowns and turnarounds are some of the most critical—and costly—events in an industrial facility’s lifecycle. Whether it’s a pulp mill, refinery, or manufacturing plant, these planned outages pack months of work into a matter of weeks. Every hour counts, and every mistake costs.
That’s why planning for quality isn’t optional. It’s essential.
When schedules are tight, contractors are many, and safety is paramount, Quality Management Systems are the thread that keeps it all together. Without it, rework, delays, and compliance issues can spiral out of control, putting both timelines and budgets at risk.
Why Quality Matters in Shutdowns
A shutdown isn’t business as usual. Crews are larger, timelines are compressed, and risks are heightened. That combination makes it easy for quality to slip—unless it’s intentionally built into the plan.
Here’s what happens when it isn’t:
Rework that eats into limited time. Discovering weld defects or improper installations late in the shutdown means scrambling to fix them, often with overtime or delays.
Suppliers falling short. If incoming materials and parts don’t meet spec, you may not realize it until equipment is already offline.
Inconsistent inspections. With multiple contractors on-site, inspection standards can vary widely, leaving gaps in documentation and oversight.
Audit and compliance risk. Regulatory bodies and clients often scrutinize work completed during turnarounds. Missing or incomplete records can put your certifications—or contracts—at risk.
The good news: these risks can be prevented with upfront quality planning.
Key Elements of a Quality Plan
A strong quality plan for a shutdown or turnaround doesn’t need to be complicated. But it does need to be deliberate. Here are the essentials:
1. Pre-Shutdown Preparation
Quality should be part of the early planning conversations, not an afterthought. This includes:
Defining inspection and test plans for critical tasks.
Reviewing supplier qualifications and pre-approving materials.
Training contractors on your quality expectations before they arrive on-site.
2. Document Control
During a shutdown, the pace is fast and the paperwork is heavy. Make sure forms, procedures, and records are clear, accessible, and standardized. A centralized digital system can prevent the chaos of multiple versions floating around.
3. On-Site Oversight
Designating qualified quality professionals on-site ensures that inspections aren’t rushed or skipped. These professionals also act as a bridge between operations, contractors, and management—keeping everyone aligned and issues visible in real time.
4. Supplier and Contractor Monitoring
With so many moving pieces, oversight of suppliers and subcontractors is critical. Conduct incoming inspections on high-risk materials, and verify contractor quality records throughout the project—not just at the end.
5. Post-Shutdown Review
Once operations resume, the work isn’t done. A structured close-out process captures lessons learned, verifies that documentation is complete, and ensures that equipment is turned back over with confidence.
Fractional Quality Support for Turnarounds
Not every company has the luxury of a full-time quality department to manage all of this. That’s where fractional quality comes in.
Fractional support means bringing in experienced quality professionals for the duration of the shutdown—whether that’s a few weeks of planning, on-site oversight, or post-shutdown cleanup. It gives you access to expertise when you need it most, without carrying the overhead year-round.
At Steelhead Quality Solutions, we’ve supported shutdowns and turnarounds across industries. Our team knows the pressure of the clock, the complexity of the crews, and the importance of doing it right the first time.
The Bottom Line
Every shutdown is an investment. The faster and cleaner the turnaround, the quicker you’re back in operation—and the more value you get from the work completed.
By planning for quality upfront, you reduce rework, minimize risk, and keep schedules intact. Fractional quality support makes that possible even if you don’t have a dedicated quality management team in-house.
Don’t leave quality to chance when the stakes are highest. Build it into your turnaround plan, and set your team up for success
