Whiting Refinery Modernization Project WRMP Oct 2012 Whiting Refinery Modernization Project

Transcription

1 WRMP Oct 2012 The Logistics Challenges of a Multibillion Dollar Expansion 1

2 BP Whiting Business Overview The refinery began operation in 1890 The 6 th 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. 2

3 WRMP competitively repositions Whiting Refinery 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

4 Key Aspects of the Project BP Confidential 4 4

5 12 Pipestill New Vacuum Tower One of the worlds largest New Crude Tower Old Crude and Vacuum Towers Super Module at dock area 5

6 12 Pipestill August 2011 October 2012 All modules and major equipment set 6

7 Coker August 2011 August 2012 All modules and major equipment set 7

8 Gas Oil Hydro-Treater August 2011 August 2012 All modules and major equipment set 8

9 Sulfur Recovery Facilities August 2011 August

10 OSBL Facilities Overall OSBL Scope Several OSBL sub-projects significantly modernize the refinery OSBL Cooling Tower #8 90,000 gallons per minute of water circulation 10

11 Coker gantry crane and holding barn Fully automated Coker gantry crane Coke barn holding 5 days product produced at 6,000 tons/day 11

12 Logistics Challenges on a Mega Project Scale 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

13 Key Material and Logistics Pattern Whiting RefineryModernization Project Foster Wheeler (EPC) COKER AG&P (Modules) Philippines International Shipment (Jumbo via Foster Wheeler) Jacobs (EPC) Sulfur (SRC) JAT (Jacobs) (Modules) Charleston, SC Fluor (EPC) GOHT OSBL 12 PS Dii (Modules) Louisiana Barges Mammoet Mammoet Site Placement Truck & Rail Non-Modular Material/Equipment Major Engineering Equipment International Shipment Mammoet to point of final Whiting location All Equipment is FAS

14 Logistics Global to Last Mile Vessels USA Spain Italy Germany Japan Korea Shipped by Jumbo Ship Ocean Barge Lake Barge Hopper Barge Freight Rail 14

15 Logistics Global to Last Mile Modules 600 New Iberia, La Goose Creek, SC Batangas, Phillipines Shipped by Jumbo Ship Ocean Barge Lake Barge Deck Barge Hopper barge 15

16 Shipping Offloads Vessels / Modules 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

17 12 PS Vacuum Tower on Deck Barge

18 IPMT Dock Facility 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

19 IPMT Dock Facility N 54 Acres, S 17+ Acres w/roll Off Ramp Aug

20 IPMT Dock Facility N 54 Acres, S 17+ Acres w/roll Off Ramp Nov

21 IPMT Dock Facility N 54 Acres, S 17 Acres w/roll Off Ramp OCT 2012

22 Engineering, Review and 3 rd Party Asssurance 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 3 rd party, Lowther Rolton Witnessed by 3 rd 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

23 12 PS Vacuum Tower Lift

24 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.

25 Heavy Haul Roads and Transports 12 PS Fractionator 25

26 Coker Module Transport

27 Site Coordination 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 Craft at peak, 9 Parking Lots Water distribution 2000/day 27

28 4 Warehouses 850K sq/ft and 13 Lay down Yards 203 Acres

29 One Whiting Parking 9 new Lots required

30 One Whiting Bus and Shuttle Routes/Schedule

31 One Whiting Snow Removal

32 47 Acres, H2 Plant, Standard Avenue Reroute Aug

33 47 Complex, H2 Plant, Standard Avenue Reroute OCT 2012

34 LR T 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?

35 12 PS Construction 35

36 Coke Drum Lifts 36