U.S. Gulf Coast (USGC) Petrochemicals Project

Fluor, in a joint venture with JGC, performed the engineering, procurement and construction of the 1.5-million-metric-tons-per-year ethane cracker and associated offsite components at Chevron Phillips Chemical's existing Cedar Bayou complex in Baytown, Texas. It is the first greenfield cracker project in the United States in more than a decade and is one of the largest and most energy efficient ethane crackers in the world.

Fluor's scope of work included engineering and construction for the outside battery limit scope as well as the direct-hire construction for the entire cracker project.

In March 2018, Chevron Phillips Chemical announced that it successfully induced feedstock and commenced operations of the new ethane cracker.

Chevron Phillips - USGC OSBL Cooling Tower

Client's Challenge

Ethylene produced by the new ethane cracker at Cedar Bayou will be used to meet the needs of the company's derivative units, which are capable of producing a wide variety of products, including resins turned into consumer and industrial products such as plastic films for food safety and preservation and polyethylene pipe for water distribution and natural gas transport.

Fluor's Solution

Fluor deployed its full suite of integrated solutions, including its self-perform construction expertise, innovative construction execution methodologies and unique scaffolding partnership to meet Chevron Phillips Chemical's cost and schedule goals. Work was led by Fluor's Houston office with assistance from its Philippines offices. At peak construction, more than 10,000 construction jobs were supported.

Fluor executed several mega-lifts at the site, erecting the major pieces of equipment used in the plant's operations. Each lift was more than 275 tons, with three of the lifts weighing more than 500 tons. The final and tallest lift, to erect a C2 Splitter (used for olefin separation) that is part of the ethane cracker, was more than 250 feet tall and weighed more than 570 tons. Two best-in-class cranes were needed to lift the unit, which weighs more than 300 cars. All lifts were completed safely and on schedule.

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Conclusion

Fluor performed engineering, procurement and construction for a new ethane cracker at Chevron Phillips Chemical's existing complex in Baytown, Texas. The ethane cracker, the first greenfield cracker project in the United States in more than a decade and one of the largest in the world, commenced operations in March 2018.