With the major overhaul carried out as part of the turnaround at the Schwechat Refinery, MAN Energy Solutions once again demonstrates its organizational talent in the cross-functional project management.
The exceptional complexity of the activities planned and carried out was the determining factor in how long the turnaround would take. So the narrow timeframe of six weeks was very challenging.
Herculean task for Field Service in Oberhausen
Under Austria’s Pressure Equipment Act, refineries have to undergo a comprehensive overhaul every six years, and it is always a highly complex task. When the turnaround for the refinery’s petrochemical operations happened between June and August 2023, PrimeServ Industries was one of 50 partner companies assisting the Austrian oil corporation with this task. Service in Oberhausen undertook the general overhaul of several machine trains that make up the heart of the refinery.
Deggendorf specifically called on and involved too
In 2019, MAN ES in Deggendorf embarked on a feasibility study for overhauling the catalytic section of the FCC plant. In fluid catalytic cracking, heavy hydrocarbons are split into light and higher-order hydrocarbons, which are then processed into gasoline or olefins (such as propylene), for example, in the refinery. The prefabrication order was placed back in 2021, as the fabrication element required relevant advance work. For the overhaul itself, Deggendorf then dispatched around 158 workers to the construction site, around half of whom were its own personnel. “The exceptional complexity of the activities planned and carried out by DWE® was the determining factor in how long the turnaround would take. So the narrow timeframe of six weeks was very challenging,” says Project Manager Helmut Zwickl, who goes on: “At the end of the day, we managed to fulfill the customer’s expectations again, with MAN ES particularly standing out among all the subcontractors according to OMV.” Successful cooperation over many years in the core business creates the basis for new projects: “Green decarbonization solutions like methanol and synthetic fuels have been positioned in the wake of the project,” Christian Obermeier from Sales in Deggendorf explains.
The OMV Turnaround 2023 in numbers:
– Major overhaul with shutdown from 29 May to 28 July 2023
– 31 projects involving approx. 3,500 employees from 50 partner companies, including around 150 from MAN ES
– 1.2 million hours worked
– 18 process heaters, 121 columns/reactors
– 93 compressors, turbines and pumps
– 513 heat exchangers, 1,800 safety valves
– 34,000 m2 of insulation and 4,000 m of pipework replaced
– 8,000 metric tons of scaffolding used
– 500,000 bolts replaced
– 2,000 bicycles used
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