Chevron El Segundo Coke Drum Reliability

Client: Chevron Products Company

Location: El Segundo, CA, U.S.

Business Segment: Energy Solutions

Industry: Fuels

Services: Engineering and DesignProcurementConstruction

Map showing the location of Chevron El Segundo Coke Drum Reliability

Executive Summary

Fluor conducted initial studies and performed front-end design work for Chevron Products Company to plan for replacement of six coke drums at Chevron's El Segundo Refinery in California. We subsequently performed engineering, procurement and construction management on the project. The development incorporated seismic upgrades to the coke structure at the El Segundo Refinery. The vertical project required extensive scaffolding and 15 major lifts ranging from 166 tons to 500-plus tons, and took place at heights of more than 250 feet. The venture was completed four months ahead of schedule, $7 million under budget, with no serious injuries or disruption to plant operations.

The new coke drums, which are three times as heavy as the Space Shuttle Endeavor, were installed. A 1-million-pound, six-derrick structure and cutting deck that covered the coke drums were also removed. The removal took place in one lift, with a 400-foot-tall crane; the largest ever brought to Southern California.

Client's Challenge

In order to help ensure the continued safe and reliable operation of the Chevron El Segundo Refinery, Chevron needed to replace the six massive coke drums that make up the core of the refinery's coker unit, which was originally constructed in 1968. After over 40 years of service, the drums were reaching the end of their useful life, leading to increasing maintenance and operational challenges.

The coke drums are a critical component of the Chevron Refinery, which supplies over 20% of the motor vehicle fuels used in Southern California and over 40% of the jet fuel at the Los Angeles International Airport. Chevron needed to replace the drums to increase reliability of the coke drum operations while taking advantage of more than 40 years of industry advances in coke drum design.

Fluor's Solution

Fluor was part of a team of engineering, rigging and construction experts engaged in the highly complex task of planning the safe removal and replacement of the El Segundo Refinery's six aging coke drums. We incorporated detailed activities associated with upgrading the drums, such as selecting and installing nuclear level-detectors. The detectors are radiation-based continuous level measurement systems providing a complete picture of the level of coke as the drum fills while also detecting nuisance X-rays from external operations such as weld examinations.

Our construction technology team provided input and feedback into all aspects of the project involving detailed lifting design and crane selection criteria. All lifting attachment designs and lift plans were reviewed for adherence to Fluor and Chevron rigging and lifting standards, as well as those of all other governing entities potentially involved.

The project used interactive planning sessions, safety commitment workshops, cutting-edge technology and strict scaffolding safety guidelines to complete the undertaking with no serious incidents or lost-time injuries.

Conclusion

The new drums were 100 feet long by 28 feet wide and weighed about 500,000 pounds. They were maneuvered through the South Bay area two at a time, on three nights. Delivery safely met the schedule established with multiple municipalities involved. The El Segundo Coke Drum Reliability project was completed four months ahead of schedule.

The Project Management Institute recognized the development with its prestigious 2015 Project of the Year Award as a result of Fluor's successful delivery of coke drum replacements for Chevron.