Setting new standards in refining project execution
A complex refinery upgrade completed ahead of schedule, enhancing safety and community trust
Zero
Serious Injuries
CHALLENGE
A major refinery on the US West Coast was facing a critical operational challenge: its six coke drums, installed in 1968, were nearing the end of their functional life. The drums are integral to the refinery’s operation, which supplies more than 20% of the region’s motor vehicle fuel and 40% of its jet fuel. The replacement effort, known internally as the Coke Drum Reliability Project (CDRP), involved complex, high-risk logistics and engineering.
The new drums were to be fabricated in Spain and delivered within a significantly compressed timeframe, four months faster than usual. However, the manufacturing partner was behind schedule and operating with a safety culture that lacked maturity.
Transporting the massive drums from the port to the refinery presented another layer of complexity. The original overland route stretched across 11 communities, many of which were affluent, environmentally sensitive areas with high traffic volumes and strict permitting requirements. A more community-conscious alternative had to be found.
Finally, the team faced the logistical and safety challenges of removing the old drums and derrick structure and installing the new equipment during a turnaround involving thousands of workers in a tightly constrained footprint. The scope also included seismic upgrades, structural reinforcements, and heavy lifts using some of the largest cranes in operation.
SOLUTION
The project team stood on a powerful shared vision established early in the project: “Be a Difference Maker.” This vision became a touchstone for all decisions and drove an unwavering commitment to safety, quality, and collaboration at every stage. Key initiatives included:
- Transforming safety culture at the fabrication site in Spain: Through regular onsite engagement, the engineering manager helped the supplier shift from a compliant to a caring and proactive safety culture. JMJ’s Incident and Injury-Free™ ( IIF™) principles were embedded through dialogue and leadership modeling.
- Reengineering logistics with community support: The original overland route was scrapped in favor of a barge and road route negotiated with local governments.
- Executing one of the most complex heavy lifts in the refinery’s history: New best practices were developed, including a “Stop the Drop” program, experiential safety development, and 15-minute increment lift plans, which involved two massive cranes operating within feet of high-risk structures.
CLIENT GOALS
To replace six aging coke drums at the refinery with minimal disruption to the community, ensuring safety, cost-effectiveness, and timely completion.
The team was able to complete the installation under budget and ahead of schedule by applying sound project and risk management principles to overcome the myriad logistical and safety challenges, while minimizing the impact to the local community.
Creating awareness of attributes that could lead employees to make mistakes helps prevent accidents.
RESULTS
The project exceeded expectations on every front. The drums were delivered and installed four months ahead of schedule and $7 million under budget. The supplier’s safety culture was transformed, earning them follow-on contracts on major international projects.
A reimagined transport plan reduced community impact and enabled a complex move through four cities with no injuries and only three minor public complaints. Inside the refinery, heavy lifts and turnaround work involving 4,000 workers were completed safely and on time, with new safety practices now embedded in future projects.
The project was later recognized with a prestigious award for excellence in project execution. But more importantly, it left a legacy of leadership, learning, and long-term cultural change.
KEY TAKEAWAYS
- A clear vision from leadership aligns teams and guides decision-making
- Embedding a safety culture the start ensures consistent performance across all partners
- Early collaboration with all stakeholders, including communities, minimizes disruption and builds trust
- Flexibility and innovation are key to navigating unforeseen obstacles
Cost Savings
Shipment and installation $7M under budget
Incident Free
Completed with zero injuries
Early Completion
Drums installed 4 months ahead of schedule
Award-Winning Project
PMI project of the year