CESK Turnaround & Maintenance

CESK Turnaround & Maintenance

Reliable cost data for detailed turnaround and maintenance estimates

Turnarounds are complex, time-critical events in which the scope, labour requirements and execution conditions can change quickly. Reliable estimates therefore depend on cost data that reflects the specific activities, resources and brownfield conditions involved.

The CESK Turnaround & Maintenance knowledgebase helps cost estimators build transparent and detailed estimates for shutdowns, turnarounds and maintenance activities. It provides structured cost data for work carried out across a wide range of disciplines and equipment types, with a strong focus on labour and rental components and selected material costs where applicable.

By working with a consistent dataset, estimating teams can spend less time creating and maintaining norms, improve consistency between estimates and gain a clearer view of the activities and resources behind the total cost.

Key benefits

• Build detailed turnaround estimates faster using ready-to-use norms, unit rates and assemblies.
• Create a transparent cost build-up from individual details to unit rates and Bill of Quantities rates.
• Estimate work across multiple disciplines using one consistent structure and terminology.
• Account for labour-intensive brownfield activities that differ from standard new-build installation work.
• Support bid preparation, tender evaluation and estimate reviews with a repeatable basis.
• Standardize estimating practices across assets, locations and turnaround teams.

How the knowledgebase is structured

The CESK Turnaround & Maintenance knowledgebase is structured in three connected levels. Users can start at the level that best matches the scope information available and trace every estimate back to its underlying components. 

Level	Purpose
Details	The lowest level of the knowledgebase. It contains the individual labour, supply and rental components used to build detailed estimates.
Unit rates	Activities or logical work elements expressed per unit of measurement. Unit rates may combine labour, tools, rental equipment and selected materials.
Bill of Quantities rates	Smart assemblies that use project inputs and quantities to generate the required unit-rate and detail components for a more complete estimate.

The Bill of Quantities level is designed to work with typical output from engineering tools, such as BoQs, Bills of Materials and Material Take-Offs. Where the input contains only quantities, CESK can add the related activities – such as handling, welding, connecting, testing or loading – to support a more complete estimate.

Broad turnaround discipline coverage

The knowledgebase covers commonly required turnaround activities across the following disciplines and supporting services:

• Mechanical equipment, including static and rotating equipment, boilers, fired heaters, valve overhauls and connections
• Cleaning and waste handling for equipment and piping systems
• Piping (ASME), including field and prefabricated piping sections, supports, testing and pre-commissioning
• Plastic piping, including HDPE/PE, GRE and GRP systems
• Electrical, including cables, motors, earthing, heat tracing and testing
• Instrumentation, including flow, level, pressure and temperature instruments, panels and systems
• Steel structures
• Scaffolding
• Painting and surface preparation
• Insulation
• Catalyst exchange and supporting site services
• Construction tools and equipment
• Temporary facilities

New tank maintenance coverage within the mechanical discipline

Within the mechanical discipline, the knowledgebase now includes dedicated Tank Maintenance content. Storage-tank maintenance requires a different estimating basis from standard new-build installation: equipment is disassembled, inspected, cleaned, repaired and reassembled under tight time constraints, often with variable labour requirements and limited access. This new content helps estimators reflect these activities in the estimate.

The available scope includes labour and supply components, with selected rental components, for work areas such as:

• Jacking and tank-bottom maintenance
• Tank wall and tank-roof maintenance
• Floating-roof maintenance
• Tank internals, railings, walkways and welding
• Fire-fighting systems
• Testing and pre-commissioning
• Miscellaneous tank-maintenance activities

Most tank-maintenance components are structured as unit-rate assemblies supported by detail-level norms, giving estimators both speed and transparency. Plate-related components can be estimated using cost per kilogram or per plate, depending on the relevant tank and plate dimensions.

Integration with Cleopatra Enterprise

CESK Turnaround & Maintenance integrates effortlessly with Cleopatra Enterprise, the project cost management software. This allows estimating teams to use the knowledgebase in a controlled estimating environment, adjust the underlying data where required and retain full transparency in the cost build-up.

Let’s get in touch

Want to build faster, more consistent turnaround and maintenance estimates? Contact us to learn more about CESK Turnaround & Maintenance and discover how the knowledgebase can support your next turnaround.