Record Breaking Project: DTA PCG Columns

DTA PCG Shutdown: The Challenge Above 100 Metres

Some shutdowns are defined by their scale. Others are remembered for the challenges they overcome.

DTA PCG was both, With nearly 35,000 SQM of Cold Insulation & 8000 SQM of Hot Insulation to be removed and reinstalled within just 38 days, the project demanded almost a year of preparation. More than 700 workmen, 50+ supervisors, 15+ management personnel and 20 dedicated quality professionals came together with one common objective — to deliver safely, efficiently and on time.

Across the shutdown area, multiple work fronts were progressing simultaneously. But among everything happening across the complex, two high-rise columns stood out as the defining challenge.

100 Metres. 120 Metres. One Unforgiving Challenge.

One column stood approximately 100 metres high. The other reached 120 metres.

At these heights, insulation work becomes far more than simply removing the existing system and installing a new one. Every aspect of the job becomes a challenge — material movement, access, manpower coordination, working at elevation, productivity, inspection and safety.

The sheer quantity of material required at such elevations meant that material movement had to be planned down to the smallest detail. There was no room for delays, because every lost hour could impact the entire execution sequence.

And once the shutdown began, the clock was running. The teams began removing the existing insulation, while dedicated resources managed the large quantity of PIR insulation scrap being generated. At the same time, preparations were underway to bring the new insulation system into application within the planned timeline.

Working Around the Clock

While the 100-metre and 120-metre columns demanded exceptional attention, the rest of the shutdown scope was progressing simultaneously across the plant.

Multiple work fronts were active at the same time, with teams working in parallel to keep the overall shutdown schedule moving. It was a continuous cycle of removal, preparation, application, inspection and clearance — with every team dependent on the progress of the next. The two columns, however, became continuous execution fronts of their own.

Quality Management was equally critical.

With such a large number of inspection points and activities taking place continuously, four dedicated quality teams of five members each were deployed for round-the-clock inspection.

Most importantly, one complete quality team was dedicated to each high-rise column, ensuring that the 100-metre and 120-metre works received continuous inspection and quality control.

The columns were not just being worked on around the clock — they were being inspected and monitored around the clock as well.

The challenge wasn’t simply to conclude the job, It was to maintain the same level of workmanship and quality from the first meter to the highest point.

A Milestone Above the Ordinary

For everyone involved, these columns became more than another item on the shutdown scope. They became a test of planning, teamwork, discipline and execution at an extraordinary scale.

From the workmen operating at extreme elevations to the teams working across the rest of the plant, the supervisors coordinating multiple fronts, quality teams inspecting every stage and management keeping the entire operation aligned — everyone played a part in making it happen.

And metre by metre, the columns took shape.

The successful completion of insulation on the 120-metre erected column marked a landmark achievement — the first known execution of insulation on a 120-metre erected column in the history of insulation.

"100 metres. 120 metres. 45,000+ SQM. 38 days. Hundreds of people. Multiple work fronts. One team working around the clock to achieve what had never been done before".

DTA PCG Shutdown: The Challenge Above 100 Metres

Some shutdowns are defined by their scale. Others are remembered for the challenges they overcome.

Across the shutdown area, multiple work fronts were progressing simultaneously. But among everything happening across the complex, two high-rise columns stood out as the defining challenge.

100 Metres. 120 Metres. One Unforgiving Challenge.

One column stood approximately 100 metres high. The other reached 120 metres.

Working Around the Clock

While the 100-metre and 120-metre columns demanded exceptional attention, the rest of the shutdown scope was progressing simultaneously across the plant.

Quality Management was equally critical.

With such a large number of inspection points and activities taking place continuously, four dedicated quality teams of five members each were deployed for round-the-clock inspection.

Most importantly, one complete quality team was dedicated to each high-rise column, ensuring that the 100-metre and 120-metre works received continuous inspection and quality control.

The columns were not just being worked on around the clock — they were being inspected and monitored around the clock as well.

The challenge wasn’t simply to conclude the job, It was to maintain the same level of workmanship and quality from the first meter to the highest point.

A Milestone Above the Ordinary

For everyone involved, these columns became more than another item on the shutdown scope. They became a test of planning, teamwork, discipline and execution at an extraordinary scale.

And metre by metre, the columns took shape.

"100 metres. 120 metres. 45,000+ SQM. 38 days. Hundreds of people. Multiple work fronts. One team working around the clock to achieve what had never been done before".