The Bayernoil refinery in Neustadt, located on a site covering approximately 300 hectares, has been in operation since 1964, producing propane and butane, refinery gas, all types of gasoline, diesel, and light and heavy heating oil. A wide range of products is also manufactured in Vohburg, including refinery heating gas and liquefied petroleum gas, as well as all fuels, bitumen, and sulfur used today. The refinery there began operations in 1967 and covers an area of approximately 127 hectares.

Our role as a partner

Since 2006, promaintain has been significantly involved in the shutdown planning and turnaround management at both sites in the areas of

• Plant technology
• Welding technology
• Infrastructure and logistics
• Contract management
• Scaffolding coordination
• Interface management

Vohburg 2025: on site again to support the customer

Preparations for the 2025 turnaround in Vohburg began last year. Ten of our qualified turnaround planners were on site to ensure that the highest standards were met.

The work, which was planned in detail in advance, had to be completed within a few weeks, so extremely precise planning was essential.

The following factors were crucial:

• Limited time – As a rule, only one month is available to complete all work. The longer the plant is out of operation, the greater the financial losses – both due to lost production and the costs incurred for personnel and external service providers.
• High coordination requirements – During the turnaround, numerous tasks must be carried out in parallel. Maintenance teams, external service providers and inspectors are all working simultaneously. Delays or logistical problems can jeopardise the entire schedule.
• Safety and compliance requirements – Hazardous substances are processed in petrochemical plants. Therefore, all work must comply with strict safety regulations to prevent accidents.
• Unforeseen challenges – Despite careful planning, unexpected technical problems can arise during the turnaround (e.g. components that are more damaged than assumed). Therefore, contingency plans are necessary to be able to react quickly.

Each turnaround is concluded with a lessons learned session – a valuable opportunity for further development and the creation of optimised solutions. In Vohburg, we were able to set up a safety centre within a few months this year to prepare the personnel assigned to TAR 2025 for risks, correct behaviour and potential errors – and thus meet our customer's high requirements.

Neustadt 2023: on site for a smooth turnaround

In 2023 we took part to the turnaround of the Bayernoil plant in Neustadt. The shutdown, which was in march, was prepared by an 8-person promaintain team together with Bayernoil and other service providers. This is the largest shutdown that Bayernoil has ever carried out at its Neustadt site.