The cost of a gap you can’t see
A refinery turnaround is the most capital-intensive event on the calendar — and delays can cost upwards of $1 million per day in lost production (API, cited via AMACS 2025). Yet across nearly every large-scale Shutdown, Turnaround & Outage (STO) programme, the biggest risk isn’t on the schedule or the shop floor. It’s in the gap between the systems meant to track them.
Scheduling runs on one platform. The ERP runs on another. And by the time a status report reaches leadership, it’s already describing where the programme used to be — not where it is now. Most operators know this gap exists. Few have closed it.
A turnaround at a real-world scale
This white paper, co-authored by Nayara Energy and Maventic Innovative Solutions, goes inside that gap — and how it played out at the Vadinar refinery, India’s second-largest single-site facility. Running a 20 MMTPA operation, Nayara’s STO programme spans more than 16,000 individual activities across mechanical, electrical, instrumentation, civil, and inspection disciplines, coordinated across hundreds of specialist contractors.
Before closing the gap, Nayara’s planning process looked like many others in the industry: sound in principle, but stretched thin by fragmentation—spreadsheets that couldn’t stay in sync, a scheduling tool with no line back to the ERP, and reporting that depended on someone reconciling all of it by hand, milestone after milestone.
What you’ll find inside
- A structured way to benchmark where your own STO programme actually stands today — and what separates the stages that follow
- The real root cause behind the disconnect between scheduling tools and the ERP, and why it’s rarely the technical problem it first appears to be
- How Nayara Energy moved from fragmented, after-the-fact reporting to a connected, real-time planning environment
- Concrete recommendations for plant and IT leadership weighing a similar shift
In their own words
“Your commitment to continuously enhancing the Procify STO Manager software… helped ensure smooth execution of key turnaround activities.”— Sathyanarayana Singh, VP & Head IT (Refinery, Marketing and Corporate), Nayara Energy Limited
