The Orica Ammonia plant on Kooragang Island is not just a crucial part of ammonia production, but also a significant contributor to the New South Wales economy. Its role in manufacturing fertilisers, explosives, and various industrial chemicals is vital for industries such as mining, infrastructure, and medical. Ensuring the plant’s operational efficiency and safety, especially during scheduled shutdowns, is paramount for maintaining these industries’ productivity and safety standards.

The scope of work for this project included a wide range of tasks necessary for the successful shutdown and restart of the plant. Specifically, BLJ was responsible for isolating and de-isolating the plant, removing end covers and channel heads from exchangers, performing various machining and pipe-cutting jobs, removing and replacing valves, and opening vessels for inspections followed by reassembly (box-up). To accomplish this, BLJ supplied a team of 18 highly skilled technicians and 2 experienced supervisors to oversee and conduct these essential maintenance works on-site.

Understanding the critical nature of the tasks at hand, BLJ In-situ Solutions deployed a well-coordinated team of professionals to execute the work scope efficiently and safely. The team’s meticulous planning and organisation ensured minimal disruption to the plant’s operations and strict adherence to the shutdown timelines, demonstrating their professionalism and dedication to the project.

The first phase involved safely isolating the plant to prepare for maintenance activities. This process was carefully managed to ensure all systems were properly shut down and secure. Technicians then worked on dismantling critical components of the exchangers, ensuring they were safely removed for inspection and maintenance.

BLJ’s team utilised advanced machining and pipe-cutting techniques to perform precise modifications and repairs, ensuring the plant’s infrastructure remained in optimal condition. Valves were removed and replaced with precision as required, ensuring that all new components met the necessary specifications and were correctly installed. Vessels were carefully opened for thorough inspections, followed by meticulous reassembly to ensure they were sealed and operational.

The shutdown project was completed successfully, meeting all safety and operational requirements. The expertise and efficiency of the BLJ In-situ Solutions team ensured that all tasks were completed on schedule, allowing the Orica Ammonia Plant to resume production without delay. The thorough inspection and maintenance activities performed during the shutdown significantly enhanced the plant’s safety and reliability, reducing the risk of future operational issues. Thanks to the precise coordination and execution by BLJ’s team, the shutdown period was minimised, ensuring that the plant could quickly return to its critical role in ammonia production.

By providing comprehensive and professional mechanical services, BLJ In-situ Solutions played a crucial role in maintaining the Orica Ammonia Plant’s high safety and performance standards. This project not only highlighted BLJ’s technical capabilities but also underscored our commitment to supporting essential industrial operations throughout Australia.