Factories sometimes need to be shut down for maintenance. This type of Turnaround is expensive given production loss and the costs of the maintenance itself. Therefore a Turnaround should be as fast as possible. Good preparation, planning, and execution with a team of professionals are crucial for success.
From scaffolding to asbestos removal
The Turnaround of the DSM Caprolactam plants consisted of the testing and certification of equipment and valves. Hertel was hired for the execution of the scaffolding, insulation, asbestos removal, rope access, and conservation. Hub Moonen is Manager Insulation Netherlands at Hertel. “The Turnaround itself took place in week 11, 12 and 13 of 2012, but we had already started our preparations early in 2011. This extensive period of time was necessary as it included the simultaneous shutdown of six factories.” DSM divided the Turnaround in two parts, requiring two separate operating project organisations, for which Hertel provided the professionals.
Hub Moonen, operational manager Hertel: “Through daily coordination with the Operations department, Hertel ensured that the operability of the installation was not obstructed.”
Scaffolding was one of the most important and complex elements of this Turnaround. The Hertel team had calculated that they would need 60,000 m3 of scaffolding. Tanks, columns, vessels, valves, cooling towers and piping needed scaffolding. More than 2,000 Cuplok scaffolding was used. During the Turnaround one hundred Hertel specialised operatives made sure all scaffolds remained up-to-date and responded to change requests by DSM. The key challenge was the provision, in close cooperation with Sitech Services, of 24/7 availability of 25 scaffold operatives for the scaffolding of the cooling towers.
The DSM plants are rather compact, which added to the challenge of positioning the scaffolds without obstructing the project. Hub Moonen: “We discussed this several times with other parties in order to find the ideal solutions. For instance, Mammoet – a hoisting company for heavy lifting and transport machinery - needed us for lifting equipment through scaffolds.” Through daily coordination with the Operations department, Hertel ensured that the operability of the installation was not obstructed. As in all Hertel projects, Safety was paramount in this project. Hub Moonen: “A year before the Turnaround we developed an HSE plan in close cooperation with DSM, which was supported by all parties. By bringing in the project leaders at an early stage, we were able to discover bottlenecks early and solutions in time.”
Our added value
Quick and successful Turnaround
Good preparation, planning, and execution with a team of professionals are crucial for success.
Safety is paramount
As in all Hertel projects, Safety was paramount in this project.
A good preparation, planning, and execution with a team of professionals are crucial for success.