Whiting Refinery Modernization Project - Indiana Logistics
Whiting Refinery Modernization Project - Indiana Logistics
Whiting Refinery Modernization Project - Indiana Logistics
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<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong> – WRMP –Oct 2012<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
‘The <strong>Logistics</strong> Challenges of a Multibillion Dollar Expansion’<br />
1
BP <strong>Whiting</strong> Business Overview<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• The refinery began operation in 1890<br />
• The 6 th largest refinery in the U.S.<br />
with 413,000 barrels per day of crude<br />
distillation capacity<br />
• Supplied by a network of pipelines<br />
that provides access to 3 distinct<br />
crude markets<br />
• Over 15 millions gallons per day of<br />
transportation fuels produced and<br />
shipped via 8 pipelines<br />
• Transportation fuel marketed at a<br />
network of terminals across 8 states<br />
• One of the largest producers of<br />
asphalt in the U. S.<br />
• Other products distributed across<br />
the country by pipeline, truck, rail<br />
and barge<br />
• Existing refinery employs about<br />
1,850 BP employs plus contractors<br />
for capital projects, TARs, etc.<br />
2
WRMP competitively repositions <strong>Whiting</strong> <strong>Refinery</strong><br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• Modernizes the <strong>Whiting</strong> <strong>Refinery</strong> with world scale assets<br />
• Processes incremental heavy sour and high TAN crude as substitute for<br />
light, sweet crude<br />
• Selective debottlenecking of fuels production<br />
Status<br />
• Completion is during second half of 2013<br />
• Greater than 75% complete with on-site construction<br />
• 28 million hours worked without a day-away from-work injury<br />
3
Key Aspects of the <strong>Project</strong><br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
BP Confidential 4<br />
4
12 Pipestill<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
New Vacuum Tower<br />
One of the worlds’ largest<br />
New Crude Tower<br />
Old Crude and Vacuum Towers<br />
Super Module at dock area<br />
5
12 Pipestill<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
August 2011<br />
October 2012<br />
• All modules and major equipment set<br />
6
Coker<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
August 2011<br />
August 2012<br />
• All modules and major equipment set<br />
7
Gas Oil Hydro-Treater<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
August 2011<br />
August 2012<br />
•All modules and major equipment set<br />
8
Sulfur Recovery Facilities<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
August 2011<br />
August 2012<br />
9
OSBL Facilities<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
Overall OSBL Scope<br />
• Several OSBL sub-projects significantly modernize the<br />
refinery<br />
OSBL Cooling Tower #8<br />
• 90,000 gallons per minute of water circulation<br />
10
Coker gantry crane and holding barn<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
Fully automated Coker gantry crane<br />
Coke barn holding 5 days product produced at 6,000 tons/day<br />
11
<strong>Logistics</strong> Challenges on a Mega <strong>Project</strong> Scale<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
Construction Statistics<br />
• 800 modules and vessels<br />
• 1,200 pieces of equipment<br />
• 380 miles of pipe<br />
• 50,000 tons of steel<br />
• 1325 miles of wire and cable (distance from Chicago to Santa Fe, NM)<br />
• 15,000 concrete truck deliveries<br />
• 95,000 truckload deliveries<br />
• 14,000 piles to be driven<br />
• 200 material deliveries per day<br />
• 9,000+ Staff/Craft on ‘One <strong>Whiting</strong>’ site at peak<br />
12
Key Material and <strong>Logistics</strong> Pattern<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
<strong>Whiting</strong> <strong>Refinery</strong><strong>Modernization</strong> <strong>Project</strong><br />
Foster<br />
Wheeler<br />
(EPC)<br />
COKER<br />
AG&P<br />
(Modules)<br />
Philippines<br />
International<br />
Shipment<br />
(Jumbo via<br />
Foster<br />
Wheeler)<br />
Jacobs<br />
(EPC)<br />
_________________________<br />
Sulfur (SRC)<br />
JAT (Jacobs)<br />
(Modules)<br />
Charleston, SC<br />
Fluor<br />
(EPC)<br />
________________________<br />
GOHT<br />
________________________<br />
OSBL<br />
________________________<br />
12 PS<br />
Dii<br />
(Modules)<br />
Louisiana<br />
Barges<br />
Mammoet<br />
Mammoet<br />
Site<br />
Placement<br />
Truck & Rail<br />
Non-Modular Material/Equipment<br />
Major<br />
Engineering<br />
Equipment<br />
International<br />
Shipment<br />
Mammoet to point of<br />
final <strong>Whiting</strong> location<br />
All Equipment is FAS
<strong>Logistics</strong> – Global to Last Mile<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• Vessels<br />
− USA<br />
− Spain<br />
− Italy<br />
− Germany<br />
− Japan<br />
− Korea<br />
• Shipped by<br />
− Jumbo Ship<br />
− Ocean Barge<br />
− Lake Barge<br />
− Hopper Barge<br />
− Freight<br />
− Rail<br />
14
<strong>Logistics</strong> – Global to Last Mile<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• Modules – 600<br />
− New Iberia, La<br />
− Goose Creek, SC<br />
− Batangas, Phillipines<br />
• Shipped by<br />
− Jumbo Ship<br />
− Ocean Barge<br />
− Lake Barge<br />
− Deck Barge<br />
− Hopper barge<br />
15
Shipping Offloads – Vessels / Modules<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• Via St Lawrence Seaway and<br />
Great Lakes<br />
− Montreal, Canada<br />
− Port of <strong>Indiana</strong><br />
− IPMT Dock Facility<br />
• Via Mississippi and Illinois Rivers<br />
− Port Allen, SC<br />
− New Iberia, La<br />
− IPMT Dock Facility<br />
16
12 PS Vacuum Tower on Deck Barge<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
IPMT Dock Facility<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• 2 Heavy Lift Berths and a Roll On / Roll-Off Ramp<br />
− 400T crane for Hopper Barge offloads and SPMT Transporters for Deck Barge Roll Offs<br />
18
IPMT Dock Facility–N–54 Acres, S–17+ Acres w/Roll Off Ramp – Aug 2008<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
19
IPMT Dock Facility – N – 54 Acres, S – 17+ Acres w/Roll Off Ramp – Nov 2010<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
20
IPMT Dock Facility – N – 54 Acres, S – 17 Acres w/Roll Off Ramp – OCT 2012<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
Engineering, Review and 3 rd Party Asssurance<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• Major Lifts for loading, offloading, transport to site or lifting at site<br />
were<br />
− Developed by EPC or Mammoet<br />
− Stamped by <strong>Indiana</strong> PE and reviewed by Independent 3 rd party,<br />
Lowther Rolton<br />
− Witnessed by 3 rd Party Heavy Lift experts from Santis or Lowther<br />
Rolton<br />
− Reviews performed with <strong>Project</strong> Lift committees as additional<br />
assurance<br />
− Several Thousand Engineered Lifts made at site alone<br />
• <strong>Logistics</strong> required to keep engineering and paperwork flowing without<br />
impacting construction
12 PS Vacuum Tower Lift<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
Heavy Haul Road Layout<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• All 34KV power lines moved<br />
underground<br />
• 138KV Transmission Lines powered<br />
down by NIPSCO for Transports<br />
over 50’ tall<br />
• Traffic Signals replaced with<br />
Swivel design<br />
• 4 K-Rated Gates installed at<br />
<strong>Refinery</strong> perimeter<br />
• New Heavy Haul roads built within<br />
refinery<br />
• Police escort from Barge facility to<br />
HH Gates<br />
• Adjacent businesses and<br />
surrounding municipalities alerted<br />
prior to Transports.
Heavy Haul Roads and Transports<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• 12 PS Fractionator<br />
25
Coker Module Transport<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
Site Coordination<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• Daily Meetings with Security, Emergency Response, Fire department, Pillar<br />
<strong>Logistics</strong> Leads, WBU Turnaround and <strong>Project</strong>s teams<br />
• Utilize Live Map, Monthly Aerial photos and Smart Boards to visualize and<br />
plan<br />
− Road Closures and Emergency response Impacts<br />
− Heavy Haul Transports<br />
− Major Crane Lifts and Heavy Equipment locations<br />
− Other Site Impacts due to SIMOP’s<br />
• Weekly <strong>Logistics</strong> Meeting – Longer range view<br />
− Staff and Craft Housing<br />
− Craft Parking and Bussing – 9000+ Craft at peak, 9 Parking Lots<br />
− Water distribution – 2000/day<br />
27
4 Warehouses 850K sq/ft and 13 Lay down Yards – 203 Acres<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
One <strong>Whiting</strong> Parking – 9 new Lots required<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
One <strong>Whiting</strong> Bus and Shuttle Routes/Schedule<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
One <strong>Whiting</strong> Snow Removal<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
47 Acres, H2 Plant, Standard Avenue Reroute – Aug 2008<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
32
47 Complex, H2 Plant, Standard Avenue Reroute – OCT 2012<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong>
LR13000 – 3000T Crawler Crane<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
• One of Largest Crawler Cranes in the<br />
World<br />
• Delivered from Germany by Jumbo<br />
Ship to Port of <strong>Indiana</strong><br />
• Offloaded in over 200 pieces<br />
• Proof Tested at 3400T<br />
• Crawler tracks over 11’ tall<br />
• Tubing on Boom and Mast is 2” Thick<br />
• Redundant State of the Art Control<br />
systems<br />
• What could you do with this crane and<br />
how would that help you?
12 PS Construction<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
35
Coke Drum Lifts<br />
<strong>Whiting</strong> <strong>Refinery</strong> <strong>Modernization</strong> <strong>Project</strong><br />
36
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