Case Study: Delivering a Smarter Turnaround Strategy for an ACMC Plant
#problem
The Problem: Rising Costs, Overworked Teams, and Critical Upgrades
In September 2025, a long-standing Orise customer faced increasing challenges managing the annual turnaround of their ACMC plant. The turnaround included critical upgrades, maintenance, and loop testing, all essential for safe and efficient operations within the plant.
Historically, these activities had been handled internally. While the customer’s in-house team had the knowledge and experience, rising labor costs, overtime, and pressure on internal teams made this approach unsustainable.
The customer sought a more efficient alternative without compromising quality or safety.
#solution
The Solution: Orise Steps In
Orise already supported the customer for several years with Electrical & Instrumentation (E&I) verification and functional safety projects on-site. This meant our engineers understood both the plant environment and the customer’s operational expectations at the outset. During discussions about the challenges experienced in previous turnarounds, our team proposed a new approach: allowing Orise to take responsibility for the loop testing, which marked the beginning of the project.
#process
The Process: Building a Smarter Turnaround Approach
Thorough preparation ensured a strong start and played a key role in the project’s success. Orise brought valuable experience from multiple turnaround projects in which we had successfully provided turnaround managers, E&I testers, and E&I troubleshooters. To ensure consistency and efficiency, Orise invested in carefully selected test and calibration equipment, even developing a demo plant environment where employees could train and familiarize themselves with the systems before arriving on-site. This allowed the team to work confidently and efficiently from day one of the turnaround.
During the turnaround itself, the Orise team consisted of four testers and one test operator, also known as a boardman. Working closely with the customer’s planning schedule, the turnaround manager coordinated which loops would be tested and when. The original planning was based on the customer’s MS Project schedule, which Orise adapted and optimized internally.
The ROI: Reliability, Cost Effective, and Future Proof
As with many turnaround projects, unexpected repair issues required adjustments throughout the process. Thanks to strong communication, flexibility and careful coordination, the team successfully completed all planned testing activities in just a single month.
Orise delivered a reliable, cost-effective turnaround, reducing internal workload while maintaining high safety and quality standards. The customer has already invited Orise’s team back to support the next turnaround planned for 2026.