Fluor worked closely with NWR during front end engineering to find solutions to reduce cost. This included a highly modularized design and innovative engineering, which resulted in significant work hours being shifted from site to the Edmonton area module yards.
Front end engineering began in 2011. Detailed engineering started in 2013 after a cost savings initiative phase and completed in 2015. In 2015, assembly of the project's 358 total modules began, 114 of which were assembled by Fluor's Supreme Modular Fabrication facility in Edmonton. Mechanical completion of the refinery is planned for 2Q-2017.
As part of this project, Fluor executed the largest lift in Canadian history with the successful raising of the 1,530-ton cracking reactor. The lift was the fourth largest in Fluor's over 100-year history. This is Fluor's largest construction project in Canada, with over five million craft hours to be worked at the job site. The scope of the project includes over 16 thousand tons of steel, 177 thousand linear meters of pipe, and 670 thousand linear meters of cable. Self-perform construction includes: structural steel, piping and electrical and instrumentation for units 10 and 30. Peak site presence is expected to be around 2,000 people, including craft and staff. Construction innovations include the use of CEMATRIXTM for optimized backfill, incorporation of engineered scaffolding systems (PERI) into the 3D model, and full implementation of advanced workface planning, setting a new standard for Fluor.