CR3 India (CRAI) was engaged in a large shutdown at the world’s largest refinery during April and May 2019.

After weeks of preparations, pre-shutdown activities, discussions with our client and subcontractors, we were ready to commence the project on the day the client stopped the hydrocarbon feed into the plant. Our crews were lined up for dayshift and nightshift operations and started to blind all battery limit valves to isolate the plant from the live refinery. Once the site was isolated, the client began to decontaminate and steam out the plant for a safe handover to all contractors to begin their mechanical activities.

CRAI’s mechanical scope was significant and included the following key activities:

  • Blinding / de-blinding
  • Scaffolding
  • Insulation: lagging and cladding
  • End to end heat exchanger maintenance including retubing of bundles
  • Fin Fan plug opening, hydro-jetting / cleaning
  • Vessel and column M&I
  • Valve dropping, repair, machining, and box-up
  • Hot works and fabrication
  • Hydro-testing after box-up of equipment
  • Bolt torqueing
  • Motor removal and installation

This multitude of activities required a large workforce that peaked at just over 1,000 during the busiest period. More importantly and thanks to a great team effort, we achieved an impressive 230,416 man-hours without incident. Our client praised this performance in a Motivational Program meeting. Also, the Vice President for Site Safety recognised CR3’s safety team for maintaining the HSE culture and safe systems of work compliance throughout this and other shutdowns at the plant.

On behalf of the Shutdown management team, we are proud to have finished another large event within schedule, with zero incidents and to have achieved a leak-free start-up. We want to express our deepest gratitude to all personnel involved and for making this project a huge success.