Interview with Sergio Navarro, Turnaround Planner, Ecopetrol, Barrancabermeja Refinery, Colombia, April – Currently Ongoing

SILICON (Q): How did you decide to become a Turnaround Planner?

Sergio Navarro (A): To be honest, I didn't know much about turnarounds in the refinery initially. My family has a history of working in refineries, but I wanted to explore other sectors. However, my first job in 2014 involved helping with a turnaround, and I enjoyed it. Over the years, I worked with different contractors and realized there were many opportunities for improvement. In 2017, I became a Planner and had the authority to implement new procedures and tools, focusing on productivity and efficiency.

SILICON (Q): Did people listen to your new ideas and approaches?

Sergio Navarro (A): Yes, I believe I made a positive impact. In 2022, I took on a corporate role as a Turnaround Runner, which gave me more authority to implement changes and introduce new technologies. Although it was challenging to convince people initially, demonstrating the benefits and conducting tests helped gain their trust.

SILICON (Q): What were some of the new technologies you implemented during this Turnaround?

Sergio Navarro (A): We introduced eight new technologies, including SILICON SpeedHex® 3 for refractory work, water blasting for hydro demolition, cold cutting with water jets and jack tracks, a new Peri-UP scaffolding system for scaffolding, drone inspections for pipes, robotic overlay welding, air hoists for heavy lifting, and gunned anti-abrasive refractory. These innovations significantly improved productivity and safety, reducing turnaround time and costs.

SILICON (Q): How did you succeed in getting approval for these new technologies?

Sergio Navarro (A): It was a challenging process. People are often resistant to change, so we had to demonstrate the benefits through tests, consultations, and testimonials from other refineries. We also conducted risk analyses and presented detailed documentation to gain approval from the technical department and management.

SILICON (Q): What was the main challenge faced during this Turnaround?

Sergio Navarro (A): One of the main challenges during the FCC turnarounds is dealing with the refractory and hex mesh. The critical path of this Turnaround involved removing refractory, removing hex mesh, cleaning the surface of the walls, welding the hex mesh, and reinstalling the refractory.

SILICON (Q): How did SpeedHex® 3 help address this challenge?

Sergio Navarro (A): SpeedHex® 3  was implemented as a solution to improve productivity and efficiency. It was the best technology we introduced because it significantly reduced the turnaround time and costs. Now, everyone wants to use SpeedHex® 3  in Colombia due to its effectiveness.

SILICON (Q): What lessons did you learn from this Turnaround?

Sergio Navarro (A): We learned a lot about implementing new technologies and the challenges involved. For example, water blasting presented logistical issues that we had to overcome. These experiences will help us improve future turnarounds. The key lesson is to be persistent, resilient, and always think about safety and innovation.

SILICON (Q): What was the most significant impact of the turnaround on the refinery and the community?

Sergio Navarro (A): The turnaround had a huge impact. This refinery supplies a considerable percentage of Colombia's fuel, so any delays would have significant consequences. Additionally, we hired over 2,000 local people directly and many more indirectly, providing substantial employment opportunities for the community.

SILICON (Q): What advice would you give to those starting their career in turnaround planning?

Sergio Navarro (A): Be curious, persistent, and resilient. Focus on safety and innovation, and don't be afraid to seek advice and collaborate with others.

SILICON Scope of work

A dedicated team of six SILICON Rapid Arc Welding (RAW) professionals has been supporting one of the largest Turnarounds in Colombia. To meet the project’s demanding scope, nine D20 machines were deployed to the site. The SILICON RAW team consisted of one Project Manager, three RAW Operating Supervisors, and two RAW Operators.

Over a period of more than two months, the team worked across several critical units and their key components, including the Reactor, Regenerator, Cyclones, Combustor, Cap, Deflector, Duct, and Area Rings. For anchoring, the solutions selected were SpeedHex® 3 and SpeedVee®, chosen for their performance and reliability in high-stakes industrial environments. The synergy within the Turnaround Team was exceptional: communication was clear, operations were efficient, and collaboration was seamless. With a straightforward, results-driven approach, the team consistently supported one another to deliver at the highest standard.

“The Barrancabermeja Refinery offered a welcoming and highly professional environment. The people were hardworking, respectful, and truly collaborative. The culture was vibrant, and even within an industrial setting, the sense of community was clearly felt. I also made lasting friendships during this project, which added a personal dimension to the experience. It felt safe, engaging, and like a place I’d gladly return to. The atmosphere on site was incredibly cooperative, everyone was focused on delivering quality work, and that kind of environment makes the job deeply fulfilling. That is why this project will always stand out in my memory.”

– Joao Pereira, SILICON Operating Supervisor

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