Nexus EPCM Expertise Ensures Chemical Manufacturing Reliability

Nexus EPCM Expertise Ensures Chemical Manufacturing Reliability

Expedited Engineering, Procurement & Construction Management Reduce Plant Downtime

Overview:

A major chemical manufacturer in the Midwest, a U.S. leader in TMP and Penta production, was facing recurring equipment failures at a critical stage in their production process. The equipment was nearing the end of its lifecycle, causing frequent malfunctions and costly downtime that threatened production of sodium formate, trimethylolpropane, di-pentaerythritol, and pentaerythritol—essential components for paints, lacquers, and synthetic lubricants.

Recognizing the urgency of the problem, Nexus Engineering Group integrated a comprehensive solution through its fully integrated EPCM (Engineering, Procurement, and Construction Management) model. Our team was tasked with not only identifying the root cause of the issue but also overseeing all aspects of the equipment replacement—ensuring seamless coordination between engineering, procurement, and construction to deliver a timely, efficient solution.

 

Challenge:

The client needed to replace their malfunctioning equipment on an accelerated timeline with minimal disruption to ongoing operations. With strict requirements for low outage time, the project had to be executed 24/7 with contractors working around the clock. Given the high stakes, the challenge was not only about fixing the problem but doing so under intense time pressure while maintaining the safety and reliability of the entire plant.

Nexus responded by deploying a team on-site, taking full ownership of the project. Our team was embedded with the client’s staff, working side-by-side to ensure the project was executed smoothly. While being on-site, our team was able to provide real-time responses to challenges, adjust to unforeseen changes, and make decisions collaboratively with the client. This level of hands-on involvement was key to the project’s success, as noted by the client.

 

Solution:

Nexus delivered tangible results by meeting the client’s critical need for fast, reliable execution. We didn’t just plan a schedule—we delivered on it. The pre-construction phase was completed ahead of schedule and construction began as planned, ensuring that the equipment replacement was executed without delays. By maintaining close coordination between our engineering, procurement, and construction teams, there was no friction between groups and all aspects of the project were seamlessly integrated.

The new equipment was installed and operational with minimal downtime, allowing the client to resume full production ahead of schedule. The upgraded equipment not only resolved the recurring malfunctions but also improved operational efficiency, extended the lifespan of the process, and reduced overall costs associated with maintenance and downtime.

By working hand-in-hand with the client and leveraging our proximity to the facility, Nexus delivered more than just a project—we provided a comprehensive, results-driven solution that directly addressed the client’s operational and business needs. This level of service and accountability is what sets Nexus apart.