Plugging the Problems-Turn Around 2018
In April 2018, owing to multiple on-going vulnerabilities,
Turnaround was taken to ensure continuous, efficient
and reliable plant operation. Unprecedented scope
coupled with extremely complex jobs requiring
simultaneous execution on a multitude of fronts
demanded very meticulous preparation and a
thoroughly professional attitude.
Some of the major jobs undertaken during the
turnaround were E-208 (Waste Heat Boiler) tubes
leakage rectification, KS Coil Reinforcement & Feed
Gas Coil Re-routing, E-506 & E-213 ½ rigging and T-1201,
T-1202, T-4000 internal inspection and repair.
Each of these tasks were safely and successfully
executed and could not have been completed in due
time without close coordination between all
interfaces.
Taming the Mammoth
Mammoth:
- A big elephant with long curved tusks (n)
- Extremely large (adj.)
I was once playing a video game called “Far Cry – Primal”. During one of the levels, in order to clear it,
requirement was to tame a wild ‘Mammoth’. However, it took more than average effort to clear the level;
either the Mammoth killed or it got killed, yet remained untamed.
If we employ the same analogy to executing Machinery related jobs during the recent Turnaround, it will
not be an exaggeration. 11 major jobs, 20+ bearing inspection, replacement of 04 dry gas seals – and that
too with no comprise on safety or quality. The amount of tasks, their complexity and available manpower;
everything seemed to be going against the odds. But like always, challenge was accepted. Bar charts
with careful calculation of hours were prepared, readiness of spares were checked and lastly tools lined
up.
A week before Plant shutdown, all assigned personnel sprung to action, gathering every possible item for
their jobs. These industrious lads worked tirelessly full circle for 25 days fighting intense heat, scarce
resource and weird tasting tea!!!
They came out of the feat as victors clocking injury free 50K+ man-hours, zero quality issues and leakage
free assemblies.
One of the senior guys said, “The team has accomplished what seemed like an impossible task that too
without getting a single nick or a scratch, Bravo!”