Reformer Unit Turnaround & Expansion Agriculture Project

ParFab successfully executed a turnaround for a reformer unit, initially focusing on KRES refractory repair, transfer lines, and hot spots. With a 30% increase in scope, additional services included piping, exchanger welding, vessel work, and hot tap nozzles, with the project concluding on schedule, showcasing ParFab's adaptability and commitment to delivering high-quality results.
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Scope Growth & Flexibility

ParFab increased the project scope by 30%, adding piping, exchanger welding, and vessel work, while maintaining the schedule.

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Manpower Expansion

The team grew from 69 to 118 employees to accommodate the increased workload, ensuring efficient resource allocation.

 
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Zero Safety Incidents

Achieved 35,200 man-hours with zero OSHA recordables, highlighting the team's commitment to safety excellence throughout the project.

Project Background

ParFab received a request to bid on an upcoming Turnaround in a reformer unit and was awarded the project on March 12, 2024. The initial work scope included KRES refractory repair, transfer line work, and addressing hot spots. After beginning the project, the client requested an expansion to include additional piping jobs, exchanger welding, vessel work, refractory, and hot tap nozzles, resulting in a 30% increase in scope. ParFab quickly scaled up manpower within days, ensuring the project remained on schedule.

Industry

Agriculture

Project Scope

Reformer Unit

Project Challenge

After starting the initial scope, the client requested an expansion that included additional piping, exchanger welding, vessel work, refractory, and hot tap nozzles, resulting in a 30% increase in the project scope.

How We Helped

ParFab quickly increased manpower within days to accommodate the expanded scope, successfully keeping the project on schedule.

Manpower

The workforce and PFS personnel needed to complete the project.

Manpower Expanded to Meet Increased Project Scope

The original project scope required 69 employees, but with scope growth, ParFab increased manpower by adding 49 more employees, bringing the total to 118. This rapid response ensured the expanded requirements were met efficiently and on schedule.

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Original Scope Personnel

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Man Hours

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Total # of Personnel

Health, Safety, & Environmental

As of September 1, 2024, the project has accumulated 35,200 man-hours with a safety supervisor on both day and night shifts, and one safety technician during the day. ParFab peaked at 118 employees, with behavior observations conducted by both the client and ParFab. Notably, the project has had zero OSHA recordable incidents.
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Project Quality and KPI Overview

This project was managed by 1 quality manager and 1 Certified Welding Inspector (CWI). The weld history report recorded a total of 200 welds, with 2 tower work operations involving overlayed rings and an installed nozzle, and 0 total rejects. Heater work included 900 sq. ft. of installed or repaired bricks, with 0 start-up leaks.

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