128 Projects.
One Refinery.
Over six years of turnaround and capital project activity, PBF Torrance used EZTRAK-supported workflows for planning, materials, field execution, QA and cost control.
128 projects: 59 unit-level turnaround events and 69 capital projects.
- ~$650MEstimated total project spend
- ~$325MEstimated labor spend
- $226.6MMaterials managed & tracked
- ~$47MModeled savings & cost avoidance
PBF didn’t need another dashboard.
It needed the work behind the dashboard connected.
Turnaround teams were working through spreadsheets, paper forms, planning tools, cost databases, dashboards, field applications, fabrication trackers and custom-built solutions.
Each handled part of the event. The complete picture still depended on people moving information between them.
EZTRAK connected those workflows into one turnaround record while continuing to work alongside SAP and Primavera P6.
SAP stays. P6 stays. The disconnected work around them gets connected.
The results
- 40%Documented reduction in contract-planner spend
- ~68%Lower readiness-window material spend$616K → $196K, 2023 vs. 2025
- <24hrsQA sign-offDown from more than 72 hrs
- 3shiftsAhead of schedule on the 2024 turnaround
~$47M in modeled savings & cost avoidance
The model is built from Torrance’s project history, tracked material spend and documented planning improvement.
Material savings & avoidance
- Tracked material spend
- $226.6M
- Modeled improvement
- × 15%
- Modeled material savings & avoidance
- ~$34M
The model captures recurring costs associated with duplicate purchases, excess and surplus, material loss, rentals, expediting, unnecessary reorders and material already on-site but not visible to the team.
One measured indicator: readiness-window material spend fell approximately 68% between 2023 and 2025.
Planning labor impact
- Estimated labor spend
- ~$325M
- Contract-planner spend, modeled at ~10% of labor
- ~$32.5M
- Documented reduction in contract-planner spend
- × 40%
- Modeled planning labor impact
- ~$13M
Together, the material and planning models produce approximately $47M in savings and cost avoidance over the case-study period.
Material management was one of the biggest gaps.
Received does not mean ready.
A material item could be received and still delay the job.
The turnaround team still needed to know where it was, whether it had been verified, whether its documentation was complete, which work package required it and whether it was actually ready for installation.
EZTRAK connected the material lifecycle:
- Required
- Ordered
- Received
- Verified
- Staged
- Issued
- Installed
Teams could see location, work-package linkage, documentation, photos and current status in one place.
That visibility reduced duplicate buying, unnecessary expediting, surplus and time spent searching for material already on-site.
During the readiness window, the pre-execution period when materials are being received, staged and prepared for field use, material spend fell approximately 68% from 2023 to 2025.
What was consolidated
PBF Torrance had accumulated more than 20 spreadsheets and paper forms, along with specialized applications handling individual pieces of the turnaround.
- Spreadsheets & paper formsMaterials, scope changes, planning, tracking and reporting
- Legacy turnaround planning toolsScope, packages and execution planning
- Desktop cost databasesBudget and cost tracking
- Dashboards & reporting toolsLeadership and project reporting
- Offsite fabrication & repair trackingShop status, photos and documentation
- Field-update applicationsExecution status from the field
- Milestone tracking toolsReadiness and progress tracking
- Planning & communication applicationsCoordination and task management
- Vendor bid & proposal workflowsContractor pricing and submissions
- P&ID lookups in the fieldAccess to engineering information during execution
- Custom one-off applicationsTools developed to fill individual process gaps
- EZTRAK reduced the manual work required to keep those workflows aligned.
Live field execution changed QA.
Before the live workflow, field completion and QA status depended heavily on manual handoffs.
EZTRAK connected field completion directly to QA, allowing the next step to begin as soon as status changed.
- QA sign-off before the live workflow
- More than 72 hours
- QA sign-off with EZTRAK
- Under 24 hours
Faster handoffs allowed teams to act while the event was still moving.
The information stays with the refinery.
Every turnaround created valuable history:
- Work packages
- Estimates
- Material records
- Actual costs
- QA documentation
- Photos
- Changes
- Contractor performance
- Lessons learned
When that information was scattered across contractor systems, spreadsheets and individual applications, the next team had to rebuild knowledge the refinery had already paid to create.
EZTRAK kept that turnaround history connected and available for the next event.
The indirect savings matter too.
More time on tools
Less time searching systems, reconciling files and chasing information.
Less manual data entry
Information was captured once instead of repeatedly re-entered.
Fewer data transfers
Fewer exports, imports, emails and manual handoffs.
Fewer one-off applications
Less need to license or build software for individual workflow gaps.
Faster decisions
Material, execution and QA issues surfaced while teams could still respond.
Better leadership visibility
Leadership received a more complete, current view directly from the turnaround workflow.
EZTRAK gave us line of sight we never had — every item, every dollar, every day. That visibility drives accountability across the whole event, and the cost savings follow.
Join our weekly newsletter
Field-level insights into how turnarounds, shutdowns, and outages actually run. No product announcements.
See what your next
turnaround could save.
Answer six quick questions and get a conservative savings estimate based on real turnaround cost drivers.
6 questions • under 2 minutes
Based on industry benchmarks and real turnaround cost drivers.