Improvement projects for maintenance and shutdown at AVR waste processing

AVR Afvalverwerking Rozenburg processes more than 1.1 million tonnes of waste a year, with roughly 70% of large waste coming from households and 30% from companies in the region. To burn the waste, the Rozenburg site has 7 incineration lines that are in continuous operation. The majority of the processed waste is converted into electrical energy by means of four steam turbines with a total installed capacity of 100 MW. In addition to this, the Rozenburg site supplies steam as a heat source to the neighbouring company Kerr McGee Pigments for its processes.

What sets this site apart is also that they have a composting plant. In addition to normal waste, a further 90,000 tonnes of plant waste is processed, producing 45,000 tonnes of compost. This is then sold to companies in the agriculture and market gardening sectors. The processed waste comes from the surrounding municipalities in the Rijnmond area and large cities such as The Hague, Delft, Utrecht and municipalities in the central Netherlands.

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Nico de Jong
Head of Maintenance, AVR, Rozenburg

Constructive co-operation with a great deal of attention to the human aspect. That's how I described the atmosphere of the improvement projects for maintenance and shutdowns that they have carried out with PDM in recent years.

Maintenance, high place on the priority list

“As a large waste-processing company, we had given maintenance a high place on the priority list for some time, simply because a large share of the processing costs consists of maintenance costs,” says De Jong. “When I started at AVR Afvalverwerking Rozenburg as Head of Maintenance in 2001, structuring and improving the maintenance process was my number 1 priority. Because the improvement process that had been started was lagging behind the targets that had been set, I decided to call in the external help of PDM. The target was further rationalisation of maintenance so that we could carry it out more efficiently and effectively, in order to be able to make a bigger contribution to the operating result.

Approach

The PDM consultants on the Rozenburg site started by analysing the complete maintenance function on the basis of the ‘Strategic Maintenance Issues’ analysis model. “Among the things that appeared was that extra attention would have to be devoted to plant management,” says the senior PDM consultant. “In order to achieve the desired plant performances, the right maintenance plans would have to be drawn up and all of this would have to be in relation to maintenance costs to be incurred.
Furthermore, work-flow management, preparation and planning of all work, and the organisation structure would have to be examined. And also shutdown would have to be evaluated, from scoping and preparation to actual execution. In this latter project, our project leader and work-preparation co-ordinator supervised the AVR employees during a short shutdown in 2002. The shutdown was completed within the scheduled time and budget."

Procedure sets

While the different projects were in full swing, PDM consultants drew up two procedure sets for the maintenance and shutdown functions. These sets covered the full organisation structure, including consultation structures, reporting and performance indicators. PDM provided procedures by training the AVR employees. The PDM project leader and preparation co-ordinator were still supervising AVR employees until the end of 2003. This made a positive contribution to the readiness to change of the AVR organisation and its employees, allowing us to successfully embed.

Result

Since the project was completed, AVR has been able to achieve its original objectives, namely an effective, efficient maintenance function. Roughly speaking, this leads to a saving of about 1 to 1.5 million Euros on maintenance costs, or more than 10%. The way is also now free for further improving plant performance.

“The results of these projects have led the management board to carry out these improvement projects at out sites in Rotterdam and Duiven too,” says De Jong. “Looking back, we can say that the project was successful and we also liked working with the PDM people very much.”

Nico de Jong
Head of Maintenance, AVR Rozenburg

As a large waste-processing company, we had given maintenance a high place on the priority list for some time, simply because a large share of the processing costs consists of maintenance costs.


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