Precision, planning and performance: Inside Redwater’s 2025 turnaround

At Nutrien’s Redwater, Alberta nitrogen facility, operational excellence isn’t just a goal, it’s a commitment to feeding the future. That commitment begins with producing essential crop nutrients that supports farmers far and wide - including ammonia, solid urea, UAN, ammonium nitrate and ammonium sulfate.

Behind every successful year of production is a strategy to keep operations running at peak efficiency. This October, that came to life as the Redwater team completed a major planned turnaround.

“Turnarounds are part of a comprehensive maintenance strategy, combining regulatory compliance with proactive asset care,” said Mike Moreau, Turnaround Event Manager at Redwater. “This year’s effort targeted equipment that had reached end of life, including the site’s primary reformer furnace, which is vital to ammonia production.” Addressing these components ensures the plant can continue to operate efficiently and safely for years to come.

A four year cycle with a unique scope

Redwater’s ammonia and urea plants operate on a four‑year turnaround schedule, but the 2025 event was far from routine. The primary reformer, the heart of the ammonia process, underwent a radiant tube replacement and installation of a new transfer line. More than 1,600 welds were completed, with the majority executed using automated welding machines for precision and consistency. 

The team also serviced hundreds of safety and control valves and inspected more than 160 pieces of equipment during the turnaround. Each activity was aimed at optimizing operational efficiency, maintaining asset integrity, and ensuring safe operations.

Positive community impact

At the peak of the turnaround, the site hosted over 1,000 contractors, in addition to Nutrien employees. This not only kept the project running on schedule, but also created a positive economic ripple effect in the surrounding community.

From the final ammonia run before the turnaround to bringing the plant back online, the entire event was executed in 81 days, which was made possible through careful planning, cross‑functional collaboration, and a commitment to safety.

Most notably, the turnaround was completed injury free. “These outstanding results reflect the unwavering commitment, diligence, and shared responsibility demonstrated by every team member, and stand as a powerful testament to our Culture of Care in action,” said Mike.

Teamwork in focus

For the Redwater team, the turnaround was more than a technical success, it showed what’s possible when expertise, dedication and shared purpose align. This included close collaboration with Nutrien’s Engineering, Technology, and Capital (ETC) group throughout the development, planning and execution phases of the turnaround.

That same spirit of teamwork extended into the field, ensuring that everyone got home safe every day. The Redwater team once again partnered with Nutrien’s safety leadership coaches to facilitate training focused on effectively leading contractor teams during field execution. The feedback was overwhelmingly positive, highlighting the training’s substantial value and reinforcing the critical role leaders play in upholding safe work practices. Building on its success, the training was subsequently delivered at Nutrien’s Borger facility to support preparations for their upcoming turnaround event.

“Collaboration across all teams and stakeholders created an environment where the focus remained on strategic problem‑solving and continuous improvement, with safety at the forefront every step of the way,” said Leiselle Harripersad, GM at Redwater. “Thanks to everyone’s efforts, we can continue delivering essential nutrients reliably and safely -- helping to feed the future for years to come. I’m proud of what we achieved together and would like to extend a huge thanks to all involved.”