In 2005 BIS Industrial Services successfully completed an overhaul on Ineos Chlor's chloromethane plant. This was the first overhaul under a  three year alliance contract led by BIS-IS, and the first of five scheduled within a twelve month period.

Key features of the alliance contract are the combination of client and BIS-IS employees within the event teams, the best use of client supplier agreements and open book planning of target man hours against agreed norms, all of which were used on this event.

SCALE AND SCOPE OF THE OVERHAUL

Planning and preparation was controlled by a preparation Engineer from BIS-IS supported by a team of planners fom both Ineos Chlor and BIS-IS.  The overhaul was completed during a two week window and included the following worklist:

•            Pressure Vessel Inspections           32
•            Relief Stream Inspections              51
•            Registered Pipeline Inspections      38
•            Vessel Cleans                                29
•             Major Projects                              2
•             Minor Projects                              6
•             Isolations                                    49
•             Electrical & Instrument Routines   25
•             Trip & Alarm Tests                     132
•             Control Valve Overhauls               23
•             Defects                                     228
•             Motor Starters                            92

1800 trade hours were expended, 40 process systems were involved and 23 sub-contractors were used.

The execution phase employed approximately 120 field personnel, including mechanical, electrical and instrumentation engineers.  Specialist sub contractors provided additional support, aided by our own offisite fabrication facilities.

The overhaul was completed 10% below the targeted man-hours, costs were under the £2M budget and the safety performance exceeded the targets set, with no reportable injuries or environmental incidents.

Of significant importance to the Client was the prompt return of an export facility pivotal to the business needs of the plant. This element of the work was returned in a shorter time frame than previously experienced.

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A number of innovations contributed to the success:

• BIS Industrial Services took on the risk for suppliers and subcontractors contracted through the client
• Key skilling for high hazard systems, critical joints, bursting discs, relief streams
• Optimisation of client management and trades, minimising costs

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The highlights of the execution phase of the event, as identified in feedback from our Client, included:

• Good Safety, Health & Environment performance
• Strong, robust management team
• Good quality of workmanship
• QA documentation available pre start-up
• Delivery to major milestones
• Remarkably few remedial punchlist items post event
• Good housekeeping
• Efficient demobilisation
• No downtime of consequence due to weather
• High quality site establishment and support facilities