Gulfstream Program (PDH, LHC-9)

Client: Dow Chemical Company

Location: Freeport, TX, U.S.

Map showing the location of Gulfstream Program (PDH, LHC-9)

Executive Summary

Dow expanded its production facilities on the Gulf Coast in Freeport, Texas and Plaquemine, Louisiana with its Gulfstream Program. Fluor performed a significant portion of the program at the Oyster Creek site.

Our scope consisted of a propylene dehydrogenation (PDH) unit and a state of the art light-hydrocarbon (LHC-9) unit. We leveraged our proven processes to recruit a large number of direct-hire craft and construction management staff to build the facility. Construction completed in March 2017.

Client's Challenge

Dow's expansion in Freeport was part of a multi-billion dollar plan that took advantage of the low prices of shale gas feedstock at the time. The PDH asset project was developed via licensed propane dehydrogenation technology. The completed plant is capable of producing 750,000 tons per year of polymer grade propylene from propane.

The LHC-9 ethylene cracker has a capacity of 1.5 million tons per year and is able to use both ethane and propane as feedstock. The Gulfstream program utilizes the existing infrastructure of Dow's largest site, one of the largest integrated chemical manufacturing complexes in the world.

Fluor's Solution

We provided engineering, procurement and construction services for the new facilities and utilized a direct-hire craft staffing strategy for construction. We executed the expansion by leveraging established processes in staff and craft recruiting strategies while staying ahead of craft availability challenges as the U.S. Gulf Coast region expanded. As part of an integrated approach, a Fluor subsidiary provided construction equipment and tools.

In addition to this strategy, our office in the Philippines also provided engineering support for the project and trained personnel to execute the design of the project around the clock. Nearly 4,000 home office, construction management and craft personnel were involved on the project at its peak. The project was awarded Fluor's 2017 Hugh K. Coble Award for excellence in project execution.

Conclusion

Fluor applied our long history of megaproject success, along with innovative solutions designed for the project, to complete the project safely and on schedule in March 2017. The project achieved more than 5 million consecutive work hours without a lost-time incident.

The Dow Ethylene Production Facility was honored in Engineering News-Record (ENR)'s 5th annual Global Best Projects competition with an Award of Merit in the Power/Industrial category. The Dow/Fluor project teams were recognized for leading the outstanding design and construction efforts of 2017. In December 2018, the project was also named a finalist for the Global Energy Awards Construction Project of the Year by S&P Global Platts.