Baton Rouge FCC Unit Turnaround

Exxon

Location
Baton Rouge, Louisiana, USA
Industry Served
Region
North America

Scope of Work

Project Management, Pressure Vessel Design and Analysis, Detailed Engineering, Material Procurement, Fabrication, Construction Planning, Construction    

Summary

Exxon retained McDermott to develop a construction plan for performing two fluid catalytic cracking (FCC) turnarounds. The upgrades for the two FCC Units (PCLA-2 and PCLA-3) included replacement of the reactors along with modifications to the structure, transfer lines and various other components.

The project was complex because the two units were located in different parts of the refinery, and both were located under regenerators. In addition, the PCLA-3 Unit was surrounded by other process units and pipe racks, allowing insufficient area for a crane. Due to space being limited, we utilized a 500 ton capacity stiffleg derrick to lift each of the three 250 ton reactor sections.

Space was not as restricted for the PCLA-2 Unit shutdown. We used a Lampson LTL-1200 crane to assemble the second reactor, which consisted of two large sections and a smaller third section. However, to access the PCLA-2 reactor from above, we had to cut the regenerator into three sections and remove it. After we installed the new reactor, we replaced the regenerator and welded the sections back together. Despite challenges during both FCC Unit shutdowns, McDermott completed the work within schedule and budget.




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