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12BILFINGERMAGAZINE02.201313advantage compared with the paper plans of yesteryear:there is a single overview list, always up-to-dateand binding for everyone.CHANGES ARE PART OF THE PLANThe schedule envisages the pre-turnaround phase formid to end September when the refinery is shut down.“Emptying the containers and the kilometer upon kilometerof pipework can take up to two weeks,” explainsJens Teichmann. Then the plant is “sweet” – with nopressure or product – and ready to be dismantled.The fact that the shutdowns may not run to plan,de spite the meticulous preparations lasting severalmonths, tends to be the rule rather than the exception.“New subprojects can emerge once the plant has beenshut down, which you simply couldn’t foresee beforehand,”says Teichmann. “Then you need 48 hours in aday.”Apart from testing, cleaning and maintenance work,the major shutdown in Rotterdam is also serving as arevamp – modernizing and upgrading the plant. Teichmannpoints to a large transverse cylinder: “That containerover there for instance, it’s due. We’re going toswap it out completely.” Measuring six meters long, almostthree meters in diameter and 5.7 tons deadweight,that is no easy task.“The container has to be properly removed from acircuit of intake and output pipes – and from a powergrid. All four meters up in the air.” Seven firms need tobe contracted and coordinated for this single projectalone: mechanics, scaffolders, insulators, electricians,instrumentation experts that dismantle and put thecontrol units back together again, as well as a cranecompany. “And Vrachtwagens,” says Teichmann. Vrachtwagens?Teichmann tries to find the German word.For six years he has spent most of his life in the Netherlands.A few moments and his mother tongue kicksback in again. Vrachtwagens – Lastwagen (trucks).Naturally, they also need a haulage company.Restarting the plant, like getting back onto the racetrackafter the pit stop, will be the most difficult phasein the entire process. You need to ensure, says Teichmann,“that nothing runs dry,” in other words, thatthere is the necessary pressure in all parts of the plant.And of course that there are no leaks and everything isabsolutely safe.SAFETY TRAINING MEDALSTo ensure the workers’ safety, each of them receivescomprehensive instructions tailored to the specific requirementsof the KPE refinery the first time they enterthe plant. It is no different in Rotterdam than with othermajor shutdowns elsewhere: before each turnaroundthere is a safety training; each time employees pass asafety examination they get a sticker on their hard hat.Hats are emblazoned with “Shell Turnaround 2009” or“Shutdown 2011 – TOTAL.” The stickers are the medals ofthe turnaround crews.Nonetheless, a hard hat with lots of stickers is a statussymbol with an expiration date. After four years ithas to be discarded for safety reasons. Hard hats madeout of fiber-reinforced phenol-formaldehyde resin aregranted another four years’ grace before employeeshave to say their goodbyes. But then there is nothingmore to be done. “At that point the men are quite sad,”says Rainer Gross. “For them it’s like they’ve given awaypart of themselves with the hard hat.” |“THIS YEAR’S LARGE-SCALEPROJECT IS ALREADY THE 5THTURNAROUND COLLABORA-TION BETWEEN KPE ANDBILFINGER SINCE 2006. WITHBILFINGER WE HAVE FOUNDA PROFESSIONAL PARTNERTHAT PROVIDES QUALITYAND SAFETY FOR A GOODPRICE AND ON SCHEDULE.”Richard Boogers, KPE, Section Head TurnaroundCalm before the storm:thousands of specialistswill begin taking the refineryapart in October.