Turnaround, shutdowns and outages

Summary

The video explores the complexities of managing a major industrial shutdown and maintenance process in a refinery. It highlights the meticulous coordination required to ensure the success of each step, from disassembling and repairing critical equipment to maintaining safety standards. With a team of over 3,000 people, the effort focuses on achieving precise timing and overcoming unforeseen challenges. The video emphasizes teamwork, flexibility, and the pride of completing such a high-stakes project, marking the successful handover of the final facility back into operation.

Takeaways

• 😀 Turning off an industrial affair is a complex process that can take days or even weeks.
• 😀 In Spain, the turnaround process involves ensuring that all operations are functioning properly, with everyone knowing their responsibilities.
• 😀 The process includes breaking down and then reassembling the refinery in a timely manner.
• 😀 Each step in the process affects the next, requiring careful planning and coordination.
• 😀 In the first week, all heat exchangers must be placed at the wash station for the inspection and repair process to work.
• 😀 The marketplace is not a typical car wash; it's a specialized industrial wash system capable of handling pressures up to 200 bar.
• 😀 The worksite involves over 3,300 people during peak periods, all working on the refinery site.
• 😀 Safety is a critical concern, with nearly 850 people dedicated solely to ensuring safety during the operation.
• 😀 Flexibility and adaptability are crucial as unexpected situations arise that weren’t anticipated during planning.
• 😀 During the revision, three major damages were identified: a faulty wall, significant wall erosion, and damage to the area where high plates are located.
• 😀 A successful repair was completed in a short time with the collective effort of the team, demonstrating strong teamwork and technical expertise.
• 😀 The final stages involved the use of a 500-ton crane and some minor repairs to the coating of containers and heads.
• 😀 The last part of the project was mechanically completed and handed over to the operational team, marking a successful turnaround.
• 😀 The team celebrated the completion but quickly moved on to focus on the next challenge, exemplifying the ongoing drive for excellence.
• 😀 The entire site works together toward a common goal, creating a sense of pride in being part of this large and coordinated effort.

Q & A

What is the main challenge in shutting down the refinery?

Shutting down the refinery is a complex process that takes several days or even weeks. It involves carefully dismantling and reassembling the refinery's components while ensuring all operations run smoothly and on time.

What is the 'turnaround' in the context of refinery operations?

The 'turnaround' refers to the process of overhauling and repairing the refinery. It involves ensuring that all individual processes are functioning properly, that everyone knows their responsibilities, and that the refinery's components are dismantled and reassembled on schedule.

Why is it important to have all heat exchangers in place during the first week?

Having all heat exchangers in place during the first week is critical to ensure that the entire inspection and repair process can proceed as planned. Without them, the process would not be able to proceed on time.

What is unique about the industrial wash station used in the refinery?

The wash station is not a typical car wash. It is designed to handle industrial parts and can withstand extreme pressures of up to 200 bar, which is significantly higher than a regular car wash.

How many people work on the refinery site during the turnaround?

At peak times, approximately 3,300 people are working across the entire refinery site to ensure the turnaround process runs smoothly.

How do safety regulations impact the work during the turnaround?

Safety is a top priority during the turnaround. There are numerous safety regulations in place that must be continuously monitored and enforced to ensure a safe working environment for all involved.

What role does the safety team play in the turnaround process?

The safety team plays a crucial role, with around 850 people dedicated solely to ensuring safety during the turnaround. Their focus is to prevent accidents and ensure that all procedures are carried out safely.

What were some of the unexpected challenges encountered during the turnaround?

During the turnaround, three main issues were discovered: damaged walls, significant corrosion in some areas, and damaged plates containing high-pressure components. These required immediate attention and repair.

What measures were taken to address the discovered damages?

The entire team worked together to implement a technical repair plan, which was completed in a short period of time. The repairs were technically excellent and ensured the system could continue functioning properly.

What was the significance of the last mechanical installation completed?

The last mechanical installation was a major milestone, as it marked the completion of all mechanical work, with the systems now ready to be handed over to operations. This was a significant achievement for the entire team.