Maintenance Shutdown Operations in High-Risk Industries: A Case Study of the Versalis Petrochemical Plant in Ferrara

This thesis examines shutdown operations through a comprehensive case study of the GP27 polyethylene plant at the Versalis Ferrara petrochemical complex, analysing the complete shutdown lifecycle from initial scoping through execution to post-shutdown evaluation. The research employs a multi-method approach combining literature review of maintenance management frameworks, regulatory analysis, and detailed examination of the GP27 shutdown. The study investigates how multiple drivers – statutory inspection requirements, internal risk assessments, maintenance policies, environmental sustainability, and strategic production objectives – converge to shape shutdown planning and execution. Key findings demonstrate that effective shutdown management requires integration of advanced scheduling tools, systematic work breakdown structures, and robust coordination mechanisms. The GP27 case achieved zero lost-time incidents while completing all regulatory inspections within schedule, illustrating how digital platforms, contractor excellence programs, and real-time monitoring enable successful execution under compressed timeframes.