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