Unit and maintenance shutdowns
Although every industrial site is different and each process unique,
the control and optimization of their maintenance is a key issue for operators,
even more so during the crucial and critical phase of shutdowns.
To ensure the smooth running of production at an industrial site, such as a refinery or a chemical plant, regulations require operators to verify their facilities through regular inspections every 3 to 6 years in order to make sure that their state of operation is without risk for people and the environment.
The implications are significant for industrial sites. They concern the reliability of installations through:
- The reinforcement of safety and security
- The optimization of equipment
- The improvement of energy capacity, by increasing efficiency and optimizing rate of use.
Historical expertise
In 1980, for the first time, the Ortec Group proposed a general offer for the management of a production shutdown for the Total refinery at La Mède. Rapidly, Ortec became recognized for its ability to organize and carry out these large-scale maintenance operations. Ever since then, it has supported major players in the petrochemical and the chemical industry: Total, BP, Shell, Naphtachimie, Exxon Mobil, Solvay, Lyondellbasell, etc.
The Ortec Group guarantees its clients the rigor and expertise of its employees as well as its tried and tested organization for maintenance shutdowns (planned shutdowns, incident shutdowns) onshore or offshore, while guaranteeing high quality work and a restart of facilities within the best possible time frame.
Attentive to the requirements of manufacturers
Constantly striving to reduce shutdown times, particularly through its methodology of planning, organization and coordination of interventions, Ortec sets up special procedures to optimize equipment operation such as system replacements, cleaning, etc.
Ortec teams conduct large-scale projects, from the planning phase to the performance of maintenance work and through to delivery. They coordinate skills in all trades and manage ongoing customer productivity issues in compliance with safety requirements throughout.
Preparation
For the preparation and supervision of shutdowns, the subsidiary of the Ortec Group, SOM Industrie, offers comprehensive services (assistance, methods, coordination and monitoring) in mixed teams (Ortec + Client team) with an in situ and connected organization.
From the definition of the work required and the management of intervention requests to on-site readings and technical files, our experts identify the constraints – environmental or organizational – and coordinate the preparation of the shutdown with the operator’s internal departments.
- the preparation and logistics of replacement parts (bill of materials, supplier consultation, management of orders and procurement);
- the choice of participants from all trades (audits, HR analysis, checks on equipment and workshop capacity);
- compliance with the jointly-established schedule for work sites and workshops;
- approval of operating tests;
- documented monitoring with the drafting of full reports on works.
Our service offering also includes the drafting of a scope of work for calls for tender, identifying resources, means and skills requirements, according to a detailed schedule.
Digital technology in support of performance shutdowns
In order to simplify interfaces, improve data quality and provide better visibility to the client in monitoring operations, the Ortec Group is breaking new ground by exploiting all available digital resources and by offering overall support with strong added value.
Digital technologies hold a prominent position in the innovative approach of the Ortec Group.
By saving time and increasing precision and performance, they improve the quality of services. During shutdowns, all the processes are digitalized. This approach promotes real-time monitoring of the work site thanks to shared documentation and a Computerized Maintenance Management System (CMMS).
Focus on Digital Forms
Digital Forms is a solution for on site-readings which operates on ATEX tablets for the areas that so require it.
The data collected is stored on secure servers, accessible at all times, and is transmitted directly to the shutdown’s coordination & control unit.
This solution, developed by the Ortec Group, makes it possible to minimize errors in readings, reduce deadlines and ensure an improved level of quality and monitoring of procedures.
The Works
The “operational” part of a shutdown is the works phase:
- equipment replacement
- opening
- cleaning or inspection of capacities
- verifications (ultrasound, penetrant testing or radiography for welds)
- metallurgy, sheet metal work, pipework services, etc.
From preparation through to after works cleanup, from maintenance to waste management, Ortec relies on synergies to offer a bespoke service in the best possible time frame.
A specific organization diagram for each shutdown defines respective responsibilities. Daily meetings update the schedule depending on progress or any new constraints. Works supervisors carry out checks during special shutdown meetings organized in advance with service providers. Once equipment is sealed, inspection can schedule a test in order to qualify the machine or the system.
Safety & Quality
Accident
Leak
Refusal to clean
The Ortec Group makes individual security and the safety of installations a priority. All of its teams are steeped in this very real culture in the performance of their missions on a daily basis. As such, they apply and share this rigor when carrying out procedures on their clients’ facilities.
Each stage of the maintenance shutdown benefits from the same degree of stringency in ensuring safety, security, production levels, process management and control of environmental impacts.
General HSE Organization
The HSE shutdown manager is the guarantor of rule enforcement at the work site.
Among other things, he/she defines the work site PHSE. With the help of their team of occupational health & safety officers, he/she ensures the application of rules in the field and coordinates the established safety management system:
- security reception
- organization of chats
- analysis of feedback from the field
- monitoring inspection planning
- verification of license compliance
- risks analysis
Based upon:
- The various versions of the prevention plan and the preliminary visit of the site
- The main HSE objectives and key points of the shutdown
- The operating modes / breakdown of risks
He/she constantly promotes awareness in personnel to meet goals with support from supervisory staff involved in daily safety management in the field.
General management and division managers are also involved through regular visits to the site and by participating in chats, inspections and the analyses of events (hazardous situations, etc.).