Client Background

A major Gulf Coast refinery embarked on an ambitious multi-phase turnaround and capital improvement project. The comprehensive scope included critical infrastructure upgrades such as compressor replacements, pump system modernizations, and rotating equipment overhauls designed to enhance operational efficiency and extend equipment life cycles.

The Challenge

The refinery turnaround presented unique workforce and operational challenges:

  • Specialized Certification Requirements: Securing a large workforce of millwrights with mandatory TWIC, Basic Plus, and OSHA certifications for refinery environments
  • Rapid Mobilization: Assembling and deploying 45+ skilled craftsmen within an aggressive four-week timeline
  • Technical Complexity: Managing precision work on critical rotating equipment requiring exact alignment tolerances
  • Safety-Critical Environment: Maintaining zero-incident operations in a high-hazard refinery setting with strict safety protocols
  • Schedule Pressure: Meeting non-negotiable turnaround deadlines to minimize production downtime and revenue loss

The Solution

Advastar delivered a comprehensive workforce solution tailored to refinery turnaround requirements:

  • Rapid Workforce Deployment: Mobilized 45 certified millwrights within four weeks, all pre-screened for required certifications
  • Specialized Equipment Expertise: Provided crews experienced in compressor dismantling, replacement, and commissioning
  • Precision Alignment Services: Deployed millwrights skilled in laser alignment and precision tolerance work for rotating equipment
  • Heavy Rigging Capabilities: Supplied personnel certified in complex rigging operations for refinery machinery movements
  • Safety-First Approach: Implemented comprehensive safety protocols and daily briefings to maintain incident-free operations

The Outcome

Advastar’s millwright staffing solution delivered exceptional results for the refinery client:

  • On-Time Project Delivery: Completed all turnaround activities within the scheduled timeframe, avoiding costly production delays
  • Budget Adherence: Maintained project costs within approved budget parameters through efficient workforce management
  • Exemplary Safety Record: Achieved over 90,000 manhours with zero recordable safety incidents in a high-risk environment
  • Long-Term Partnership: Client consolidated all future refinery staffing needs through Advastar based on proven performance
  • Operational Excellence: Successfully restored refinery to full production capacity with improved equipment reliability