Petroleum Refining Projects

Irving Oil Limited awarded Fluor a contract for engineering, procurement and construction management of this major refinery upgrade project in Saint John, New Brunswick, Canada. The scope of facilities includes crude and vacuum oil distillation, catalytic distillation, gasoline desulfurization, alkylation, sulfuric acid regeneration, sulfur plant tail gas treater,amine sulfur recovery, sour water stripping and associated support systems.

• Construction performed through both self-perform construction and through subcontracts to construction companies from all over North America, including New Brunswick
• New process units include one of the world's largest residue fluid catalytic cracking units
• Engineering and procurement was a joint effort by Fluor offices in Canada, the United States, the Philippines, and India

Fluor provided engineering, procurement, construction, and commissioning services for the Rayong Refinery Company's grassroots refinery project in Rayong Province, Thailand. This complex 145,000 BPSD refinery supports the Royal Thai Government's need for additional petroleum products for Thailand's rapid economic expansion. Fluor engineered and designed the off-sites, utilities, tank farm, interconnecting pipeways, jetties/topsides, the power plant (a 97MW power plant is included with the refinery), hydrogen plant and hydrocracker.

• Fluor's ability to program manage joint venture projects and to provide expertise across all disciplines allowed us to successfully complete the project three months ahead of schedule
• The project was awarded Thailand's National Safety Award for construction, which recognized the project as the safest construction site in Thailand. The lost-time frequency rate was 0.03 per 200,000 hours worked. Thus this Fluor project in Thailand was 40 times more safe than the U.S. construction industry average
• Our Rayong Refinery Project incorporated the highest level of automation capabilities of any project in the oil and gas industry, thereby streamlining efficiency

Fluor was contracted by OMV to perform the Engineering, Procurement and Construction Management for the Isomerization and HDS-2 Revamp Project. Fluor performed fast track execution of the EPC phase on a Lump Sum Services basis. The project included extensive modifications of existing facilities and for the isomerization unit, a new reactor and stabilizer section, DIH Column and overhaul of H2- compressors; for the HDS-2 Unit, a new high pressure section and the revamp of the existing compressor.

The project was very successful and exceeded all targets set, as follows:

• The project was executed without a recordable incident
• Mechanical completion of both Units was achieved ahead of schedule
• The performance test of both Units was successful and achieved ahead of schedule
• The project budget was under-run
• The project received the European Construction Institute (ECI) “Project of theYear 2004” Award

Shell Canada Ltd. awarded Fluor the engineering, procurement and construction of the Primary Process Units (PPU) of its Athabasca Oil Sands Downstream Project, located in Fort Saskatchewan, Alberta.

• This facility has a design capacity of 155,000 barrels of dry bitumen per calendar day
• The facility includes a crude/vacuum unit and an 80,000 BPSD, two train LC-Finer hydrocracker. In addition to the primary process units, the project includes hydrogen production, a sulfur block and offsites and utilities
• Fluor was also responsible for engineering, procurement and construction of associated modifications to Shell's adjacent Scotford Refinery in a joint venture arrangement

Syncrude Canada Ltd. awarded the engineering and procurement of its Upgrading Expansion (UE-1) project to Fluor in a joint venture team. The UE-1 project increased Syncrude's production of sweet synthetic crude by 98,000 barrels per day.

• The scope of facilities for UE-1 included the addition of a fluid coker, diluent recovery unit, light gas oil (LGO) aromatic saturation unit, hydrogen generation unit and sulfur plant and the revamp of several process units in the existing Fort McMurray, Alberta, facility
• A web-enabled collaboration system was implemented to share plans, procedures and reports with 14 work locations around the world.

Fluor participated in the preparation of the basic design package and prepared the project specification for this gas-to-liquids plant in Bintulu, Malaysia. This included the specifications for the Fischer-Tropsch synthesis (gas-to-liquids) plant. Fluor also assisted Shell in updating the project specification for late developments and preparation of the capital cost estimates, auxiliary and utility systems.

• The first facility to utilize Shell's proprietary technology to convert natural gas into liquid fuels
• The project included the following units: Shell gasification process, air separation unit hydrogen manufacturing unit, heavy paraffin synthesis, water distillation and heavy paraffin conversion and distillation