Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Delivering Quality and Cost Control for a Complex Polymer Plant Construction
- Polymer Manufacturing
- International polymer manufacturer
- International polymer manufacturer
- New high-performance polyethylene (HPPE) unit as part of a brownfield expansion
Obstacles Our Experts Have Transformed into Opportunities
A global polymer manufacturer undertaking a brownfield expansion for a high-performance polyethylene (HPPE) unit was struggling during construction:
Unclear Design, Excessive TQs
Technical queries (TQs) and change orders were piling up due to vague design deliverables
Spec Misinterpretation & Rework
Contractors were interpreting specifications differently, leading to rework and tension with vendors
Missing Technical Guidance
The project lacked a dedicated technical advisory layer to translate design intent into construction execution
Material Delivery Mismatch
Material deliveries were misaligned with construction sequencing, causing idle labor and cost overruns
QA/QC Delays & Document Chaos
QA/QC documentation was disorganized, delaying mechanical completion certification
Progress with Risk of Breakdown
Construction progress was being made—but at the cost of coordination breakdowns, scope creep, and missed cost control opportunities.
TEEC’s Expert-Led Solution
Our Experts activated their Project & Construction Technical Advisory service as a central engineering assurance function:
What Our Experts Did
to realign maintenance strategies by risk
Introduced a customized Reliability-Centered Maintenance (RCM) framework tailored to failure modes
plans using live monitoring data
Built a Spare Parts Criticality Matrix to optimize inventory and reduce redundancy
Deployed a Maintenance Excellence Framework with clear KPIs, templates, and cross-functional ownership
Deployed a Maintenance Excellence Framework with clear KPIs, templates, and cross-functional ownership
Execution Approach by Teec’s Experts
- Assigned a TEEC Construction Technical Advisor to act as liaison between EPC, vendors, and the owner’s team
- Reviewed all IFC (Issued for Construction) packages to detect gaps, inconsistencies, or missing data
- Implemented a unified system for tracking technical queries (TQs), NCRs, and deviations
- Reviewed over 100 vendor documents including FAT procedures, installation guidelines, and ITPs (Inspection & Test Plans)
- Led technical resolution of submittals and deviation requests from vendors during fieldwork
- Audited contractor QA/QC activities for welding, painting, and mechanical installation
- Prioritized high-risk construction activities (tie-ins, lifting, pressure testing) for increased oversight
- Conducted daily field walkdowns and interface checklists across civil, mechanical, and E&I disciplines
- Flagged sequence clashes and resolved scope misalignments before they caused downtime
- Delivered weekly Technical Health Reports, combining safety, quality, and technical risk metrics
- Facilitated tri-party alignment meetings with the client, EPC, and TEEC to ensure visibility and decision support
- Maintained a live punch list dashboard, expediting closeout and mechanical completion readiness
Results & Impact
Resolved 93% of outstanding technical queries within the first 2 months
Achieved mechanical completion 1 month ahead of the revised schedule
Prevented $1.1M in potential change order cost overruns through scope alignment and deviation management
Enabled full documentation handover for QA/QC, enabling a smooth transition to commissioning
Integrated Value Through Teec’s Data-Driven Solutions
Data-Driven Solutions
BPM Solutions
With this integration, construction oversight evolved from reactive issue-tracking to predictive control.
