Houston Controls

LyondellBasell Refinery, Pasadena Texas, 2010 -2011

Fluid Catalytic Cracker Turnaround and Capital Expansion

This large, long duration project (Over 16 months total support required, over $50M Project value ) was a routine turnaround combined with a large capital expansion of the Cracker and Reactor vessels and instrumentation. High voltage substation maintenance, a complete re-validation of the Safety Instrumented Systems (SIS) control system, and addition of complex compressor control loops was also to be performed.

Houston Controls supported this project "From the ground up", providing:

1. Specialized Planners and analysts during the planning phase
2. IEA Supervisors and leads during mobilization and execution
3. A flexible and motivated technician force for the duration of the execution period, working on a 24/7 basis to meet the extremely work intensive schedule.

Houston Controls personnel worked closely with Plant personnel to assure:

1. Optimum planning of work, (over 1500 separate maintenance items for IEA were planned and executed)
2. Accurate execution of Job tasks and Capital expansion work.
3. Collection of vital Plant information (As-found ranges and data that was missing from Plant files)
4. Daily, accurate, and useful job status and progress reporting
5. Documentation of SIS testing
6. Generation of loop folders and test and inspection packages
7. Troubleshooting expertise when unexpected issues arose.
8. A "Zero injury" turnaround

Although the overall project duration was extended due to Mechanical difficulties, IEA work was completed below budget, and met all criteria for success. Careful interaction with the client resulted in a tight, efficient, focused execution force that could “hit the ground running”, fulfilling all objectives, (including zero injuries) and working with maximum flexibility to attain ultimate success. Although the LyondellBasell Refinery is a unionized facility, Houston Controls technicians were readily accepted due to the high level of professionalism and effectiveness apparent in their skills, and their willingness to work closely with the plant forces.