Digital Completions in Plant Modifications and Upgrades
Unlike greenfield or any new build construction projects, plant modifications and upgrades present a unique set of challenges. Work is carried out...
A key workflow integral to all brownfield projects, completions is the final step to quality assured project delivery. It can go very wrong or very right and, either way, will create a lasting impression of the project’s success. A digital Completions Management System (CMS) addresses the two-phase transfer of responsibility from the project team back to the owner-operator: Complete Phase and Handover Phase.
The Complete Phase ensures that the project is delivered to specification and quality standards. The Handover Phase ensures that the plant, facility or asset is fit for purpose and ready to be brought online, energized or decommissioned. These two phases, together, need to be managed in such a way so that the handover is both effective and safe, guaranteeing dependable, maintainable and operable project deliverables.
In spite of its criticality, completions processes remain overlooked in terms of upgrading traditional ways of working and reliance on outdated methods and legacy systems. A digital Completions Management System (CMS) such as MODS Connect Completions streamlines critical workflows during both the Complete and Handover Phases for transparent, responsible project delivery that enhance relationships and reputations.
The transition from brownfield construction or maintenance projects back to operations is typically where delays and cost overruns occur. Manual and spreadsheet-based tracking often leads to missing documentation, incomplete testing and last-minute firefighting. Digital solutions such as MODS Connect Completions ensure seamless tracking of system readiness, automate punch list prioritization and enable a smooth handover with structured, verified data.
Let’s be frank: all projects require a handover, making completions workflows and oversight essential for all projects. Here, let’s drilldown on three types of brownfield projects that are poised to benefit hugely from CMS: decommissioning, turnarounds and shutdowns, and plant upgrades and modifications.
A detailed comparison of how digital completions solutions impact these brownfield project types follows:
Project Type | Key Challenges with Existing Systems and Practices | How Digital CMS Improves the Process | Areas of Biggest Impact |
---|---|---|---|
Decommissioning |
- Complex regulatory & environmental compliance. - Poor records and archives (undocumented modifications, lost records). - High-risk work (hazardous material handling, structural integrity concerns). - Unpredictable costs & scheduling. |
- Automated ITR tracking ensures quality-assured delivery. -Digital archives ensure all documentation is up to date. - Digital weight control streamlines logistics for removed components. - At-the-ready data aids proactive decision making to benefit budget and schedule. |
- Quality-assurance - Risk management - Cost/schedule control |
Turnarounds & Shutdowns |
- High-pressure, time-sensitive environment. - Multiple teams working on high volumes of simultaneous tasks. - Manual tracking of ITR progress leads to miscommunication and delays. - Incomplete or delayed testing prolongs restart times. |
- Up-to-date ITR status and reliable document management. - Visibility enables proactive turnaround scheduling and resource allocation. - Mobile access for field workers ensures instant updates and coordination. - Automated certifications processes accelerates startup. |
- Schedule optimization - Workforce coordination - Startup efficiency |
Plant Modifications & Upgrades |
- Interfacing with live operations increases complexity and safety risks. - Scope creep due to undocumented conditions. - Managing multiple system integrations without disrupting production. - Environmental health and safety risks when upgrading older infrastructure. |
- Digital ITRs ensure safe, quality-assured testing alongside live operations. - Digital punch lists ensure all system integrations are verified before handover. - Automated documentation streamlines approvals and signoffs. |
- Change management - Minimizing production disruption - Quality assured delivery |
Read more about how digital completions management improves project delivery for these brownfield project types in the following blogs:
The impact of implementing a CMS in the delivery of all brownfield projects cannot be understated and include a 50 percent time savings in finding project information, an increase onsite safety and reduced closeout schedules. Decommissioning and turnarounds are arguably the most time-sensitive and high-risk brownfield project types where certifications, weight management, digital ITRs and reporting and have the biggest impact. Plant modifications and retrofits benefit hugely from accurate asset data, real-time work tracking, and change management tools, ensuring smooth integration with existing infrastructure. In all cases, digital completions reduce downtime, improve safety, assure quality and streamline reporting—areas where legacy systems and manual methods struggle the most.
Unlike greenfield or any new build construction projects, plant modifications and upgrades present a unique set of challenges. Work is carried out...
Turnarounds and shutdowns are among the most critical—and stressful—phases in the management and operation of industrial assets. These planned...
Offshore decommissioning and asset retirement present significant logistical, regulatory, safety, fiscal and reputational challenges. The process of...
Unlike greenfield or any new build construction projects, plant modifications and upgrades present a unique set of challenges. Work is carried out...
Offshore decommissioning and asset retirement present significant logistical, regulatory, safety, fiscal and reputational challenges. The process of...
Turnarounds and shutdowns are among the most critical—and stressful—phases in the management and operation of industrial assets. These planned...