- Tight Oil Processing Flexibility Project
Our team provided engineering, procurement and construction for the Tight Oil Processing Flexibility (TOP Flex) project under a guaranteed maximum price contract. The initiative involved construction of a new light straight-run (LSR)/naphtha splitter tower in an ISBL area, reusing two existing towers as debutanizers, and the installation of OSBL piping and electrical infrastructure to support the new unit. The project is designed to allow the owner to take advantage of locally available, lighter slates of crude. By installing the new tower, the owner will be able to remove throughput bottlenecks in other units, as well as improving the overall processing flexibility for the refinery.
One significant project challenge was constructability. Due the layout and space limitations in the refinery, the new TOP Flex unit was sited over an existing storage tank. The storage tank and existing area equipment had to be demolished, and existing area piping had to be rerouted before major construction could begin. Additionally, the project was surrounded by existing piperacks, making access more difficult. Orchestrating the overlap of construction disciplines and limiting the planned craft density was a key factor for successful construction.
The TOP Flex project was unique in its emphasis on processing flexibility and reuse of existing refinery equipment. The existing LSR/naphtha splitter is being converted to a debutanizer, but the capability is being maintained to put the existing tower back into its original service. This flexibility, combined with significant reuse of existing equipment, allows a maximum return on the project while minimizing the capital investment.
- Front end planning (FEP) services and process development
- Detailed engineering design
- Construction management
- New 30,000 BPD LSR/naphtha splitter
- New LSR/naphtha splitter tower
- Reuse of two existing towers
- GMAX execution
- Quantitative proof/metric