We started this project in the Definition phase, and despite not having the benefit of completing early phases, we made sure to conduct multiple onsite visits and walkdowns with the customer and provide onsite PE support. Our in-person attendance at 3D Model and Constructability Reviews ensured that the project was successfully completed and installed. We are proud of our team’s exceptional work and look forward to continuing to provide top-notch services to our clients.

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C&I’s efforts spanned over 8 years to complete all phases. Over that time, the team adapted the project scope to address client and vendor changes, all while under close corporate observation with the high price tag.

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Due to geographical constraints, the project combined three substations into one. This resulted in multiple cutovers spread over 5 years to match turnaround outages. To make space for the new substation, several storage areas had to be relocated. After installation, the project finished $3MM under budget with minimal RFIs from construction.

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Through our ASHRAE level 2 energy audit, the proposed scope reduced kilowatt usage by 1,626 hours per year. Our team’s out-of-the-box approach resulted in significant savings and favorable payback. Taking an in-depth review of the facility, beyond the typical ASHRAE updates, we were able to identify unique applications for reducing electrical energy usage.

“The individuals who work in refineries everyday were impressed with the ideas and thoughts our team created. We were able to identify energy savings where no one else could.”

John Droste, C&I Project Manager

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The project will design and commission equipment which allows for continuous, closed loop treatment of ASO within the HF Alky unit.  As a cost savings, existing equipment will be repurposed where safety or integrity is not compromised. Drawing upon our experience from other refineries, our process team scaled the technology to match refinery flow rates based on comparison of ASO to Caustic ratios from other existing units. Our support on this project extended beyond creating a cost estimate, we also attended our client’s presentation to management. We not only care about project design, but the entire project process and are here to help our clients in any way we can!

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The team was challenged to integrate new gear into the already congested operating unit. Our open communication and interactive project management style allowed us to involve maintenance, operations, and construction to balance project objectives and meet stakeholder needs.

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The criticality of this electrical gear required extensive planning to ensure the deenergizing and energizing did not result in any loss in production or safety incidents. Our team designed the equipment layout and purchased a new building to house the gear. We coordinated construction, operations, and maintenance to develop a staging plan for demolition and install.

Scope to accomplish this included larger capacity transformers, 13.8kV arc resistant switchgear with additional feeder capacity, new current limiting reactors and interconnecting cable bus. 

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A key component of this project was repurposing dated, idled equipment, requiring C&I involvement in fit-for-service evaluations. As part of this effort, we modified the charge heater to change the burners and add a burner management system that wasn’t there before. This required installation of a SIS infrastructure, which was used to support temperature monitoring on reactor and burner management system.

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There were three streams that the system could not recover, therefore C&I identified a method for recycling them back to the plant. By recycling these streams, we were able to save $3MM in total installed costs. We were one of the first to install this new compressor and worked directly with the vendor (SIHI) to ensure smooth engineering and install and to provide a reliable system for emissions reduction.

The site selected for the compressor required significant prep work, including filling in a pond and reworking drainage to other sewer systems. Our team routed over a mile of large bore piping, including a new pipe bridge, to tie the systems together.

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