UNO-VEN FCC Revamp Project

Fluor was awarded the project management, preliminary engineering, detailed engineering, procurement and contracts for UNO-VEN's Fluid Catalytic Cracking (FCC) Revamp Project. Fluor was the prime contractor for the construction management and turnaround maintenance for the revamp and expansion of the FCC unit, which utilizes UOP technology. The FCC Revamp Project combined eight projects plus turnaround maintenance into a single consolidated project.

Fluor's scope of work covered both capital and maintenance in the FCC Unit, with the single item being the complete replacement of the reactor head, plenum and cyclones. The goal was to increase unit capacity, operating flexibility, reliability and on-steam efficiency and to allow for future expansion.

Client's Challenge

FCC unit turnarounds are among the most hazardous in refinery construction. The heavy lifts, extensive scaffolding, catalyst dust, confined space, outgassing from old refractory and manpower density all contribute to safety hazards. To maintain current production levels, it was important for Fluor to engineer the new work so that it could be done with limited disruptions to the ongoing operations.

Fluor's Solution

Constructability was stressed early in the engineering phase. Design was led from Fluor's Houston office, with a goal to design for maximum installation while the plant was in operation and minimize disruptions.

The overall scope included:

Regenerator cyclone modifications - modified regenerator cyclones to reduce catalyst losses and to improve reliability for three-year runs by reducing erosion
FCC riser outlet and cyclone modifications and reactor modifications
Overhead cooling
Replacement of air heater ignition system
Light Cycle Oil (LCO) Quench
Electrostatic Precipitator (ESP)
Replacement (in kind) of existing spent catalyst expansion joint with refractory
Turnaround maintenance for reactor/regenerator area
Replacement of existing regenerator expansion joint with a new cold wall design

Fluor's network helped achieve significant savings, including the use of a 1,000-ton primary lift crane provided by a Fluor subsidiary.

Fluor Constructors International Inc. was responsible for the construction management.

Conclusion

Fluor completed the turnaround project in August 1994 on time and significantly under budget. The entire project was completed without a lost-time incident.