To perform the work effectively in this over-heated market, Fluor utilized six different locations for the design of this project. Fluor's collaborative communication systems, processes and design automation tools were keys to successfully coordinating the collective efforts of the globally distributed engineering execution, global procurement and module fabrication efforts, and site investigation surveys of the existing facilities. To ensure a high degree of quality in the performance of such a significant amount of new and revamp work, detail planning from the outset, aligning of the EPC schedule with the critical site milestone completion dates, and early identification of existing refinery conditions, were required.
To help compliment the local craft workforce, that would ultimately peak at well over 2,000 personnel, Fluor utilized modular construction in the various construction areas. Large modules were fabricated for process areas and piperacks in portions of the delayed coking unit, sulfur complex and distillate hydrotreater, including selective offsite and utility facilities.
Fluor utilized some of the world's most innovative construction technologies and tools for this project in performance of the work at site. On the initial critical path was the setting of the coke drums, accomplished in setting an industry time record, 19 weeks from first pile to setting of the drums. To support the change in construction execution by utilizing a maximum amount of local contractors, Fluor applied their MasterPlant® Suite of Project Automation Tools to improve communication and quickly create construction work packages while working with MPC to award the work to over 40 local contractors. Fluor utilized their 3D CAD plant review stations at the jobsite to help visualize and effectively status and manage the construction effort. These tools were used at the weekly subcontractor coordination meetings, providing a clear road map for the subcontractors to plan and communicate their respective work fronts.
HSE on the DHOUP project was world class. The project successfully integrated Fluor's HSE program with MPC's HESS program to successfully manage the labor onsite. Fluor's commitment to health, safety, and environment resulted in more than 8 million work hours of self perform and subcontracted labor onsite without a lost-time incident and 2 million hours without a recordable incident.