Downstream - BP Whiting OCC (Operation Canadian Crude)
Refinery Project

The BP Whiting OCC Project is a downstream Refinery Heavy Oil Upgrade project, requiring the fabrication, load-out and tie-down of 354 process modules and pipe racks. The modules were fabricated at DII’s 95-acre East Yard in New Iberia, Louisiana. Owner-furnished materials and equipment included over 2,000 truckloads of supplies in excess of 1 million individual components.

Fluor and Jacobs were the agents representing BP for the project, with Fluor responsible for 279 modules and Jacobs responsible for 73 modules. All materials, with the exception of insulation, paint, miscellaneous and shorts, were supplied by the client. All structural steel for the modules was fastened with bolts. The structural steel was pre-fabricated with holes drilled, gussets and base plates installed and galvanized. The piping was supplied, prefabricated and painted in maximum lengths of 40 feet with wear pads and pipe shoes installed.

The 352 modules weighed a total of 28,000 tons, consisting of:

• 13,000 tons of structural steel
  
• 78 miles of pipe
  
• 34 miles of heat trace
  
• 55 miles of insulation
  
• 15 miles of cable tray
  
• 35 miles of wiring

DII applied 19,000 gallons of paint to the modules and 6,300 hydro-tests were conducted on the piping.

When completed, the modules were loaded out on barges and shipping to the refinery location via the Gulf Intracoastal Waterway and the Mississippi River.

Downstream - TOTAL Petrochemicals – Deep Conversion Project

Subcontracted by Fluor Enterprises, DII self-performed fabrication of pipe rack modules in support of TOTAL’s Port Arthur refinery expansion. At our Lake Charles yard, DII constructed and installed 123 modules including the following units: a 50,000 barrel-per-day Deep Conversion unit (50-feet wide by 50-feet high by 80-feet long); 4 massive coke drums (12 stories tall, 32-feet wide and 10 to 390 tons each); a vacuum distillation unit that prepares coker feed; a desulphurization unit; a distillate hydrotreater; a hydrogen purification (PSA); and other associated units. In addition to the units, the power supply for the refinery was modernized by connecting the new entity to the 230 Kv network.

DII was also responsible for material receipt, material preparation, structural steel assembly, piping fabrication, painting, hydrostatic testing, steam tracing, cable tray installation, insulation and preparation for load-out. From our Lake Charles facility, the modules were loaded onto barges and shipped over 100 miles to TOTAL’s Port Arthur Refinery for installation. Field labor peaked at approximately 400 employees with 775,000 man-hours worked.

Upstream - Module Fabrication for Odoptu First Stage
Production (FSP) Project for ExxonMobil’s Sakhalin Island Facility

DII entered into contract with Fluor Transworld Services to perform module fabrication and load out in support of Fluor’s Odoptu First Stage Production (FSP) Grass Roots Oil & Gas Onshore Processing Facility Project for ExxonMobil’s Sakhalin Island Facility. Odoptu is an oil and gas field, located on the northeastern Sakhalin continental shelf in the Sea of Okhotsk approximately 6 miles offshore and approximately 43 miles north of the Chayvo Field.

The project provides for Odoptu oilfield hydrocarbon production, hydrocarbon processing, and transportation of oil and gas mixture to Chayvo OPF for further processing. Project implementation allows (annual average) output of 35 kBD gallons of sales quality crude and 80 million standard cubic feet per day of natural gas. 

DII fabricated eight process modules and three pipe rack modules at our Lake Charles fabrication facility, with a combined total weight of 1,724 metric tons. Our scope included welded assembly of structural steel, pipe fabrication and installation, equipment installation, E&I, insulation and testing.

All modules were assembled on specially designed, pre-fabricated concrete pads. Modules were built as low to the ground as possible to minimize working at heights and to maximize productivity. Modules were shipped more than 5,100 nautical miles to ExxonMobil’s Sakhalin Island Facility for installation. During construction, peak manpower required 400 employees with zero lost time accidents.