Premature shutdown of the plant avoided: Bilfinger supports bp with the construction of 3D scaffolding

  • Scaffolding erected to a height of 65 meters with complex structural and safety requirements
  • Innovative 3D scaffolding design improves planning reliability and transparency
  • Bilfinger impresses with fast implementation under heavy time pressure

Bilfinger relies on innovative technologies for the planning, design and implementation of industrial scaffolding. For urgent maintenance work on a section, a so-called column, at the bp refinery in Lingen, which needs to be cleaned, Bilfinger was able to digitally simulate and implement the complex scaffolding requirements in a very short time. Instead of an elaborate industrial scaffolding along the entire length of the column, a special scaffolding platform at a height of 65 meters meeting the highest structural and safety requirements was planned and implemented within a tight deadline. Bilfinger brought its digital expertise to bear to help bp avoid a premature plant shutdown.

“We have been partners for many years at the bp site in Lingen and know the challenges of the site very well. This knowledge allowed us to simulate and implement a solution quickly and pragmatically”, says Ingo Halfter, Managing Director . of Bilfinger arnholdt GmbH. “Industrial scaffolding is a critical factor for many trades. Thanks to our innovative solutions, we can ensure smooth planning and implementation as well as full transparency for our client.”

The area to be cleaned inside the column was a major challenge for the bp team and Bilfinger arnholdt: the column had to be operational again as soon as possible to avoid significant costs. A column is a process engineering device in the form of a thin pillar and is an important part of the refinery production process. Thanks to the long-standing cooperation and excellent communication between Bilfinger arnholdt and bp, a feasibility study for the scaffolding was completed in a very short time. The decisive factor here is that bp has outstanding expertise in 3D plant design and that Bilfinger was able to integrate this information seamlessly into the digital simulation of the scaffolding design. In this 3D model simulation, the entire construction process can be simulated, a crash test can be performed, or material lists can be created for logistics planning and costing. The virtual preliminary planning using CAD software and the digital transfer of the data into a structural analysis program for the precise calculation of the maximum loads were particularly useful in this project. Only by simulation could the exact position of the scaffolding legs and the weight of the structure with intelligent load distribution be determined and the scaffolding was finally made available in the shortest possible time.

“Thanks to the long and close cooperation with Bilfinger, we were able to quickly come up with a joint solution. Our requirements for the construction of the scaffolding and the deadline did not make things easier, but Bilfinger was able to intervene quickly and offer a solution innovative,” says Sarah Morris, shift superintendent at bp Lingen.

“The required construction was so complex that at the beginning it was not even clear whether it was even possible. A credible feasibility study could only be implemented on the basis of a numerical simulation. This approach facilitates completely new solutions in scaffolding construction”, explains Marcel van Helden, responsible project manager at Bilfinger arnholdt.

In addition to 3D simulation for feasibility studies of complex industrial scaffolding, Bilfinger uses various numerical approaches to continuously optimize scaffolding construction. The bp refinery in Rotterdam uses the Bilfinger customer portal to maintain a real-time digital overview of the amount of scaffolding on site. The client portal can be used to view all relevant scaffolding data, including scaffolding specifications, financial contract agreements and an overview of scaffolding locations. The emphasis is on transparency and efficiency. Scaffolding is used by various trades and can be a crucial cost item in the construction and maintenance of factories. The transparency thus created helps to ensure that any unused scaffolding is dismantled on time, helping to reduce costs.

Bilfinger has been supporting bp worldwide for almost a decade in a variety of services including maintenance, factory automation, industrial scaffolding, insulation technology, safety consultancy, pipe construction and fabrication of ovens.

Bilfinger arnholdt looks back on more than 115 years of company history as one of Germany’s leading industrial scaffolding service providers. The company, which specializes in industrial and specialist scaffolding, height access technology, insulation technology and corrosion protection, employs more than 1,500 people at its headquarters in Oberhausen and its seven other branches in Germany.

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