In 2008, BP – one of the world’s largest oil and gas companies – began the multibillion-dollar Whiting Refinery Modernization Project (WRMP) for their flagship refinery in Whiting, Indiana. BP is investing in Northwest Indiana to modernize the Whiting Refinery to enable it to process more heavy crudes. The modernization is essential to the long-term viability of the refinery, and includes significant environmental improvements. The modernized refinery will provide Whiting with the capability of processing up to about 80 percent heavy crude, versus about 20 percent today. The WRMP is the largest and the most complex refining project undertaken in BP’s recent history with almost every processing unit being modified to some degree.
Graycor Industrial Constructors recently completed two different projects as part of the WRMP at the BP refinery: 1) Six Drum Delayed Coker Unit No. 2 for Foster Wheeler USA Corporation and 2) Coker Material Handling System for Kinder Morgan Bulk Terminals, Inc.
On the first project, Graycor worked with Foster Wheeler to build a Six Drum Delayed Coker Unit. There was an immediate push to rig and install 35 major structures, pipe modules and process vessels in less than three months’ time. The team used a PTC 3,500 ring crane, one of six in the world, for the major erection activities. Through careful planning and drawing on Foster Wheeler and Graycor’s heavy lift experience all equipment was installed safely and successfully. The two largest lifts, a 600 plus ton fractionator vessel and a 700 plus ton pipe module eclipsed Graycor’s largest previous lifts. Graycor also installed another 250 pieces of equipment and erected 1,600 tons of structural steel.
The project with Kinder Morgan involved the construction of one of their largest pet coke material handling facilities. Graycor was awarded the contract to construct foundations and the above grade conveying systems. Working within the confines of a 121-year old refinery created its own set of challenges due to the vast amount of underground obstructions, but Graycor was able to successfully turnover the key foundation and proceed with the next phase of the project. The project included structural steel erection, conveyor and pipe systems installation and insulation and fire protection related to the above grade materials handling system.
These successful projects further enhances Graycor’s long standing resume of process-related projects which include recent projects for Aux Sable, Calgon Carbon, Cargill and Praxair.