The Challenge

Ecopetrol faced a highly time-critical and technically complex operation. The catalyst change-out, including internal inspections, scaffolding, and repairs, had to be completed within a strict 23-day shutdown window. Several factors increased the complexity:

• A requirement to perform part of the work (R-2601-A) before the official shutdown to reduce overall downtime
• Coordination with multiple stakeholders for internal inspections and technical condition (TC) assessments
• Existing catalyst performance concerns, requiring detailed inspection and reporting
• Limited workspace, especially in the HCM unit
• Pressure from competitors offering shorter execution times

Beyond execution speed, Ecopetrol needed a reliable partner capable of delivering safe, high-quality work, accurate inspections, and a well-structured plan based on proven experience.

Our Approach

Mourik developed a phased and optimized execution strategy to meet the Ecopetrol’s  operational and technical requirements.

Smart Phasing Strategy

The project was split into two phases:

• Pre-shutdown (Pre-TA): Catalyst change-out in reactor R-2601-A using local teams
• Shutdown (TA): Simultaneous work on R-2601-B and HCM reactors (R-2651 / R-2653) with additional specialized personnel

Optimized Resource Deployment

• Deployment of experienced specialists for larger, more complex vessels
• Use of local Mourik teams for smaller units to reduce mobilization time and cost
• Strategic use of equipment, including:

• Vacuum trucks with cyclone hopper systems
• MCU unit for high-volume catalyst handling

Equipment was efficiently relocated between units to maximize productivity and minimize idle time.

Enhanced Inspection Support

Mourik supported Ecopetrol during internal inspections by providing video recording and detailed reporting of internal conditions, and identifying issues. These insights enabled our client to plan future maintenance more effectively.

Safety-Driven Innovation

For the first time, two reactors in the HCM unit were unloaded simultaneously despite limited space. Mourik ensured safe execution by:

• Developing a detailed plot plan
• Safety awareness training of personnel
• Defining safe zones for equipment, forklifts, and personnel
• Implementing controlled movement and access strategies

 Dust Control & Environmental Measures

• Scaffolding was used to confine unloading areas
• Pneumatic vacuum systems captured catalyst dust during operations

The Result

By combining technical expertise, strategic planning, and strong collaboration, Mourik exceeded Ecopetrol’s expectations, delivering a faster, safer, and more efficient catalyst change-out while providing valuable insights for future operations. The project was safely completed 3 days ahead of schedule.

We are proud of the positive impact delivered by our team:

 Operational Excellence

• Project completed in 20 days instead of 23 (3 days ahead of schedule)
• Improved planning for future shutdowns based on inspection findings

 Safety Performance

• Zero accidents
• Zero incidents
• Zero medical cases

 Environmental Impact

• Reduced catalyst dust emissions through effective containment and extraction measures

 Compliance

• Full compliance with Colombian regulations, including permits, certifications, and workforce documentation

 From initial planning to daily on-site coordination, Mourik maintained full transparency and alignment with our client, ensuring continuous optimization throughout the project.