The planned turnarounds of the Platformer-Unifiner units started on April 01st, 2012 for a period of 30 days. The Platformer-Unifiner shutdown has been scheduled to follow immediately after the No.1 Visbreaker and Ker Rerun units (1VBU / KRU) which are currently under a turnaround.
The planning and preparation of these process units are carefully done by dedicated teams of highly qualified personnel several years prior to the turnarounds. All possible factors are taken into consideration by these teams to ensure highest safety standards to employees, contractors and surrounding country and minimal revenue loss is incurred to the Company.
The scope of the Platformer-Unifiner shutdown T&I consists a major overhaul and upgrade of the recycle compressor gas turbine GT3650; routing of platformer vent gas to LSDP flare; inspection and repair of around 130 major pieces of equipment such as reactors, furnaces, columns, heat exchangers, control valves and safety relief valves; regeneration of Platformer and Unifiner catalyst; unloading, screening and dense loading of fresh/regenerated catalyst of Platformer and Unifiner reactors; repair and replacement of more than 50 Kms of piping systems of various types and sizes, in and around the units; complete overhaul and seal replacement of Platformer Gas compressor K3650 and a significant Instrument and Electrical scope.
At its peak, around 700 Company and contractor personnel will be engaged on the Platformer-Unifiner shutdown. The majority of these will be working around the clock and it is expected that around 200,000 man-hours will be worked.
Shutdowns are inherently hazardous activities and this, in conjunction with the large number of people engaged on the shutdowns, demands that, as with all Maintenance activities, much emphasis has been placed on environment, health and safety (EHS) matters. Many detailed risk assessments have been carried out for the high risk activities and a detailed Environment, Health, Safety & Medical Plan has been prepared. This has been issued to and will be disseminated amongst all Bapco and Contractor personnel involved in the shutdowns. Contractors have also been encouraged to promote safety and run safety incentive schemes.
The turnaround activities which will be carried out under supervision of Maintenance Division will also ensure participation and full involvement of Refining and Engineering Divisions. Support from Human Resources and Administration and Finance & IT Divisions will also be key in ensuring logistical issues are adequately addressed.