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Published byEstella Wilcox Modified over 9 years ago
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2006 BAYTOWN TURNAROUND Unit could not sustain full rates after Hurricane Rita Planned Turnaround for 3Q06, moved forward to 1Q06
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SAFETY Combined owner and Contractor TRIR of.86 Over 463k combined owner and Contractor man-hours One contractor recordable injury suffered de-torquing of exchanger bolts One owner recordable injury suffered during electrical substation troubleshooting of a routine maintenance job 13 first aids documented. 35 near misses documented. Over 31,000 hazards mitigated or eliminated Over 5,500 permits written Falling objects were the biggest safety challenge
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QUALITY Weld repair rate of 3% One flange leak on start-up One major rework involving the blow out of a heat exchanger tube plug on start-up
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SCHEDULE Turnaround planning effort approx. 40% complete when the signal was given that the T/A would begin in 2 months Work completed one day ahead of schedule (52 days) Schedule challenged by turnover rate of approximately 40% by key Contractors. Leveraged in-house Contractors to overcome turnover. Worked 7 days per week on all work. Major vessel refurbishment was anticipated critical path but, ultimately the major overhaul on our Gas Turbine became critical path.
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COST Met overall cost objective Escalating labor rates accounted for 4% of the budget Contractor productivity better than plan by 6% Repairs in the major vessels less than anticipated
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OTHER Long lead material delivery challenged schedule No issues regarding equipment availability
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