Austria: Challenge ‘Turnaround’ Pörner To Cope with Three Major Revamps

Editor: Dr. Jörg Kempf

In April 2016, at OMV in Schwechat (Austria), the TAR 2016 took place. Pörner Ingenieurgesellschaft Vienna, and its subsidiary EDL Anlagenbau Gesellschaft Leipzig, mechanically completed and handed over three revamp projects to OMV concurrently, during this stop.

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Schwechat refinery
Schwechat refinery
(Picture: © OMV Aktiengesellschaft)

Vienna/Austria –The aim of the 6-year cycle turnaround is to increase the availability and safety of the plants for the next running period, while simultaneously improving efficiency throughout the refinery. The three major revamps (reactor exchange of the desulfurization plant, improved product yield of DEA2 and RD4 plant, increase of production yield of crude oil distillation plant) had to be finalized almost at the same time within the stop. This meant an engineering, processing and most of all, a planning challenge for the Pörner and EDL engineers. They drew on the experience of more than 60 projects under the label “Revamped by Pörner”, that have been realized in the last ten years in accordance with the schedules and budgets.

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“Under ‘Revamped by Pörner’ we strive for triple optimization: first, the engineering — we provide all engineering services from a single source in a complete package for the customer — then, the realization — we ensure a precisely structured schedule for the shortest possible standstill production — and thirdly, in terms of the optimized operation — our aim is that our client has smooth future plant operation, in which all production processes are perfectly matched, so that our client has a competitive plant for years to come,” explains Andreas Pörner, CEO of Pörner Group.

Overall, the turnaround involved 13 plants for its modernization, OMV invested € 40 million. 12.6 km pipes were renewed and 306 tons of steel were processed. Up to 2,500 additional employees logged 600,000 work hours. The 15 projects meant about 35,000 work packages — all scheduled to align with the core time of the TAR in April 2016.

The engineers of the two Pörner Group locations have utilized their advantages and special expertise for the project — the Viennese engineers with their project management, knowledge of the site and proximity to customers, and the colleagues in Leipzig with their process engineering competence, vast experience in planning, preparing and logistics planning for revamps. Thus an optimized project structure was created, the efficient and tailor-made management concept offered customers the triple optimization emphasis.

OMV now sees itself, thanks to the new features and enhancements from the turnaround 2016, well prepared for the future in the international competition. The Pörner Group in turn is pleased with three more “Revamped by Pörner” reference projects that were effectively completed. It resulted in a satisfied customer as well as a successfully optimized plant in every respect, and Pörner is grateful for the confidence placed in it from one of the leading oil companies in Europe.

In addition to the mechanical completion of the three major projects during the TAR, the Pörner Group was also responsible for the integrated scheduling of the entire OMV stop. Further details on the next page ...