Plant Shutdowns
Major maintenance execution during plant shutdowns: retubing, ASME repairs, hydrojet cleaning and integrated procurement in a single contract.
In short: An industrial plant shutdown (turnaround) is the most critical and costly maintenance event of an industrial facility. INCALCA has been the maintenance partner of Venezuela's leading industries during their plant shutdowns for 36 years. We arrive on day one of the shutdown with full personnel, materials and equipment ready, and operate in 12-hour shifts (or continuous 24-hour shifts when the window is critical) until the committed scope of work is complete.
An industrial plant shutdown (turnaround) is the most critical and costly maintenance event of an industrial facility. INCALCA has been the maintenance partner of Venezuela's leading industries during their plant shutdowns for 36 years. We arrive on day one of the shutdown with full personnel, materials and equipment ready, and operate in 12-hour shifts (or continuous 24-hour shifts when the window is critical) until the committed scope of work is complete. Our ability to scale to more than 300 simultaneous professionals allows us to cover multiple work fronts in parallel within the same shutdown.
Pre-Shutdown Planning and Preparation
The success of a plant shutdown is determined well before the plant stops. INCALCA works with the client during the planning stage to ensure everything is ready on Day 1.
- Scope meeting with client technical team
- Review of inspection plans and work procedures (PTW)
- Advance specification and procurement of materials: tubes, gaskets, valves
- Execution plan: work sequence, resources, milestones
- Safety condition review: confined spaces, energy isolation
- Pre-mobilization of heavy equipment and special tools to site
Multi-Disciplinary 24/7 Shift Execution
During the shutdown, INCALCA operates multiple work fronts simultaneously under a single technical coordination.
- Heat exchanger retubing during shutdown (multiple units in parallel)
- Boiler repair and retubing under ASME R stamp
- High-pressure hydrojet cleaning of entire exchanger battery
- Leak repair: emergency welding on vessels and lines
- Safety and control valve maintenance
- Piping and rotating equipment assembly and disassembly
Quality Control and Documentation
Every activity performed during a plant shutdown is backed by quality records that the client can use for internal audits and regulatory requirements.
- Rolling records: depth and torque for each tube
- Hydrostatic test certificates signed by AI of National Board (ASME equipment)
- Welding records: WPS applied, welder identity, LP/UT inspection
- Material certificates: MTR for all installed tubing and materials
- Daily progress report with completion percentage per work front
- Final AS-BUILT dossier of all interventions
Deviation Response Capability
Every plant shutdown reveals additional unplanned work when equipment is opened. INCALCA has the technical capacity and personnel to absorb these deviations.
- Additional standby personnel to absorb extra work
- Stock of common materials on site for immediate response
- Urgent procurement capability for unplanned special materials
- Work reprioritization coordination with client per schedule
- Direct communication between INCALCA superintendent and client shutdown manager
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