BHP Billiton Kwinana Nickel Refinery (KNR), WA

Project

Major Outage Success : ATIVO Shutdown Services delivers another great result.

  • 25,000 man hours
  • 19 day outage
  • 140+ Crew
  • Outcome based delivery

Client

BHP Billiton Kwinana Nickel Refinery (KNR) completes a total plant outage approximately every three years and was looking to increase plant reliability and subsequent efficiencies with their next outage not planned until 2011, some 4 years away. The KNR March 2007 outage was one of BHP Billiton’s largest maintenance activity in WA this year. They therefore needed to be very selective on their partners to protect their key asset.

Scope

ATIVO were awarded a competitive tender to complete services under an outcome based risk / reward model, in the Oxy Reduction area of the plant. The scope included pre-shut planning and work pack review, execution, responsibility for all works & successful handover of plant upon safe completion of works.

The actual scope involved included:

  • Isolating the plant
  • Removal of all items for off site repair (OSR)
  • Vessel openings to allow hydroblasting, inspection and NDT.
  • Resultant remedial works
  • Installation of all OSR items
  • De isolate plant and handover

Crew

The team to manage the delivery of these outcomes required a project manager, two superintendents and were supported by a supervisory team of 14 including 2 OSH professionals. ATIVO utilised its permanent shutdown crew for the 145 personnel required which included mechanical fitters, boilermaker welders, riggers and trades assistants.

Outcome

The Post Shut review identified the following highlights:

  • 1758 x Safety Observations vs. target of 1212. (~150% KPI)
  • ZERO Reportable Incidents (including, MTI and LTI)
  • 170+ work orders completed
  • 25,239 hrs completed
  • 96% ATIVO Shutdown Crew Retention (6 new starters to the team)
  • 100% Pre Mobilisation Drug & Alcohol Screens
ATIVO’s Shutdown Service is a tailored solution designed to meet client’s specific needs. All shutdown managers, planners, supervisors, and tradesmen undertake the ATIVO Accreditation Program which ensures that our crews are competent to work safely and productively with zero harm to people, plant and environment.