Steel, Equipment & Piping Installation

Project Summary

We were the self-perform mechanical contractor for rebuilding above ground mechanical and electrical installations at a Midwest refinery, working with Burns & McDonnell as the general contractor. We direct-hired and managed all union labor for work on the refinery's crude unit, fluid catalytics cracker, alkylation unit, and outside battery limits (OSBL) pipe racks and ancillary facilities. This included:

• Erecting structural steel
• Setting and alignment of equipment
• Routing of static and rotating equipment
• Installing and testing of process systems and components
• Installing steam trace systems

We also managed and self-performed the receipt and distribution of all owner-supplied direct materials off-site.

Our team was integral to heavy equipment lifts for the crude and fluid catalytic cracking (FCC) areas. Multiple lifts were over 100,000 pounds, and more exceeded 50,000 pounds. Several new towers ranging from 60 feet to 175 feet in height were part of the heavy lift package. A new reactor was also welded on the top of the existing regenerator structure in the FCC unit.

Key material quantities:

• 2,300 tons of structural steel
• 194,000 linear feet of pipe
  • Average pipe diameter is 4.5 inches
  • 11,000 field welds
  • 11,000 pipe supports
• 310 pieces of equipment installed
• 2,700 cubic feet of grout