Mechanical Turnaround at Lyondell Botlek

About Client

In 2023, Lyondell Botlek required a comprehensive mechanical turnaround for its BDO plant. This initiative also included the first phase of the RHI project, involving a high-pressure steam pipeline. The primary objective was to ensure the plant was fully prepared for operation within a short timeline. With a combination of scheduled maintenance and unexpected repairs, the project required precise execution and detailed planning.

Our Activities

Dismantling, inspecting, and reassembling heat exchangers
Opening and closing vessels
Isolation and de-isolation of towers
Valve and control valve disassembly and assembly
Safety device disassembly and assembly
Welding repairs
Piping work
Repair/replacement of large, thick-walled high-grade valves, including preheating and annealing

Challenge

The turnaround presented a broad mechanical scope, including demanding tasks like welding repairs on high-grade materials and valve replacements requiring preheating and annealing. Compliance with PED regulations and NOBO guidelines was mandatory, adding layers of complexity.

Unforeseen issues across various sections of the plant necessitated swift resolutions, and safety remained a top priority throughout the process. Coordinating these multifaceted activities required seamless planning and execution.

Scope of work

The project involved a year-long preparation phase led by an in-house team that meticulously converted work orders into actionable tasks while incorporating inspection requirements.

During the execution, the team carried out equipment inspections, welding repairs, and extensive piping work under rigorous safety and compliance protocols. The discovery team handled unexpected challenges efficiently, ensuring all plant sections were operational on schedule.

Furthermore, risk analyses and structured turnover systems supported the smooth progress and timely completion of the turnaround.

The Result

The turnaround was completed on time, with all mechanical tasks meeting the highest standards of quality. Comprehensive safety measures ensured a secure working environment throughout the project.

Effective collaboration with Lyondell allowed for smooth execution, and the discovery team addressed unforeseen issues promptly, supporting a successful and timely plant startup.

Questions? Our Experts Are Here to Help You!

Edwin Koops

Division Director Mechanical