Risk management and downtime minimization during a plant shutdown

LyondellBasell is one of the world's largest plastics, chemical and refining companies. The products and technologies of LyondellBasell are used to make packaging, electronics, automotive parts, home furnishings, construction materials, biofuels and more. The company manufactures at 55 sites in 18 countries, and has 3 sites in the Netherlands. The main office of LyondellBasell Europe, Asia and International is based in the centre of Rotterdam.

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The challenge

PDM was asked to assess the plant shutdown of LyondellBasell's key installation in the Rotterdam area. This occured in combination with a material expansion of the production capacity of this installation. The primary goal was to minimize downtime and to manage the involved risks into a sustainable shutdown.

The shutdown was a combined activity with improvement projects, regulatory inspection work and debottlenecking projects. Due to the high impact on operations it was necessary tot manage risks and coordinate the complete process.

The approach

PDM used the STOP program to assess the shutdown. As a major part of the STOP program the integration process involved a project team, but also a technical preparation planning and scheduling team, as well as our proprietary turnaround management software NSpace.

Several external parties, engineering contractors and egineering partners were involved. Inplant employees were trained where appropriate and involved in the project. PDM became the overall project coordinator to control and mitigate risks.


The risk mitigation and implementation project was completed according to the clients expectations and with excellent results. Thanks to the professional approach all the key objectives were realised.

Henk de Boon
Site Manager Moerdijk, Basell Benelux B.V.

PDM has helped us significantly in steering the approach, and we benefitted through their expertise and methodology in turnaround optimisation processes.