More than 170 Esso employees and contractors formed a single cohesive shutdown team, tasked with inspecting, repairing, upgrading or replacing a significant amount of critical equipment in the Plant. The project amounted to more than 290 work orders.
As part of the shutdown, the team completed two compressor services and an engine replacement, replaced four compressor suction and discharge valves (each weighing close to two tonnes), worked on 83 pressure safety valves, completed 22 pressure vessel inspections (including two towers) and were also able to upgrade the Tricon system.
Shutdown Coordinator Sami De Marchi said a major highlight was the replacement of the plant flare tip.
“This was the first time this flare tip had been replaced in Gas Plant 3, so a significant milestone and achievement for our team to complete that work very efficiently and safely. Gas Plant 3 is now well-placed to be running on all cylinders until its next scheduled Shutdown in 2022,” said Sami.
Longford Plants Manager David Anderson said the success of the shutdown was a testament to the skill and teamwork exemplified by each and every member of the team.
“Safety and efficiency are born out of cohesiveness, so we were eager to instill a ‘one team’ philosophy from the very outset.
“A key part of this was mobilising the entire workforce into an Olympic Games-style shutdown village. This ensured a culture of communication and collaboration was developed quickly between supervisors and different work groups, who together delivered a gold medal-worthy shutdown performance,” said David.