Substation Infrastructure
Substation Infrastructure
Chevron Refinery
Project Background
Site work and foundations for new substation and electrical distribution infrastructure. Included Installation of power poles and conduit to support construction of new substation.
Scope
- Earth moving
- Grading
- Paving
- Underground
- Masonry
- Mechanical Piping
Challenge
Substation site was in an inaccessible hillside behind a main active refinery pipeway.
Solutions
We constructed temporary access over the pipeway for mass excavation and construction of a 35-foot tie-back wall and secondary wall. Because of the topography and site access, we excavated and sloped the entire slope, constructed the wall to full height, drilled tiebacks then installed and tensioned through the new wall in concert with the wall backfill. We removed the old pipeway for access and constructed a new pipeway above and around the substation — completing the piping tie-ins without disrupting refinery operations.
Multiple power pole foundations of differing designs for the main feeder were constructed for the 115Kv feeder lines into the substation, some up to 10 feet in diameter and more than 40 feet deep and others being large pile-supported concrete foundations with 15 to 20 piles each. We constructed all underground duct banks as well as the elevated substation foundation and associated structural steel. New distribution pole foundations were constructed, again with some being large deep drilled piers and other being pile-supported hollow concrete poles.
Project Success
Provided constructibility for routing of new pipeway, allowing us to successfully transition into construction of the actual substation.
Project Value
$3 Million
Quarry Firewater
Quarry Firewater
Chevron Refinery
Project Background
Tank Site Work which included removal of 300,000 cubic yards of hillside, processing of removed material and re-installation of processed material to facilitate new quarry firewater tank.
Scope
- Earth Moving
- Grading
- Paving
- Underground
- Masonry
- Mechanical Piping
Challenges
The client had selected a location for the new firewater tank to maintain proper pressures to the refinery firewater system without the addition of pumps. Engineering asked us for constructibility of new foundation and execution.
Solutions
While the original design showed removing hillside and importing new structural fill material from local quarries for the foundation, we processed the existing removed material for uses as the structural fill.
Project Success
Our innovative approach resulted in a client cost savings of $2 million.
Project Value
$5 Million
CVX/EBMUD RO Plant
CVX/EBMUD RO Plant
Chevron Refinery
Scope
- Expand plant to receive and process EBMUD reverse osmosis water.
Challenges
We needed to install 3,500LF of 316 stainless steel pipe from EBMUD to Chevron’s treatment facility. This work included site excavation and grading, concrete foundations, installation of pumps and filter, pipe racks and critical tie-ins during the plant shutdown.
Solutions
Before construction began, we noticed the project was designed with a standard sewer system. We helped redesign and construct a sewer system that met process refinery requirements.
Project Success
We completed the project on time, under budget and 100% injury-free. Plants were able to receive, treat and use most all of the Richmond plant outfall waste, which reduced or eliminated discharge to the San Francisco bay.
Project Value
$4 Million
Fresno P&DC Asphalt Replacement
Fresno P&DC Asphalt Replacement
United States Postal Service
Project Background
Fresno P&DC operations and employee lot asphalt replacement included the removal and replacement of 170,000 square feet of existing asphalt concrete.
Scope
- Critical Scheduling
- Excavation
- Asphalt Paving
- Striping / Pavement Markings
Challenges
Project needed to be performed in an operational facility.
Solutions
Management and leadership came up with solution with the postmaster to allow for continuous operation of the postal facility. Coordination included phasing and swing shift work.
Project Success
We completed the project with no interruption to facility operations.
Project Value
$500,000
Sacramento P&DC Asphalt Replacement
Sacramento P&DC Asphalt Replacement
United States Postal Service
Project Background
Remove and replace existing 54,000 square feet of asphalt concrete, concrete curb, gutter and sidewalk.
Scope
- Critical Scheduling
- Excavation
- Concrete curb, gutter & sidewalk
- Asphalt Paving
- Striping/Pavement Markings
Challenges
- Project needed to be performed in an operational facility.
Solutions
Management and leadership came up with a solution with the postmaster to allow for continuous operation of the postal facility. Coordination included phasing and swing shift work.
Project Success
We completed the project in two days with no interruption to facility operations.
Project Value
$500,000
Sulfur Recovery Loading Rack
Sulfur Recovery Loading Rack
Chevron Refinery
Project Background
Civil construction of eight new concrete foundations and one loading rack foundation, to facilitate erection of structural steel and installation of mechanical piping to support the new loading rack and its necessary pumps, structures and amenities.
Scope
- Project Specialties
- Pile Driving
- Excavation
- Grading
- Underground
- Electrical
- Masonry
- Paving
- Structural Steel
- Mechanical Piping
Challenges
Maintaining unimpeded access to the current loading rack while completing civil/structural, mechanical and piping installation for the replacement sulfur truck loading rack to increase the truck loading capacity and improve safety.
Solutions
By coordinating with operations and traffic plans during the 12+ month project to off-haul sulfur at the existing loading rack, we assisted in constructing the new loading rack without impeding necessary truck traffic.
Project Success
The new rack and its necessary foundations were safely completed.
Project Value
$5 Million
Pipe Support Replacement Project
Pipe Support Replacement Project
Chevron Refinery
Project Background
Civil construction to widen and increase the mass of 57 existing concrete foundations and upgrade the baseplates and structural steel on 40 bents.
Scope
- Project Specialties
- Excavation
- Underground
- Masonry
- Structural Steel
Challenges
Completing seismic repairs and upgrades to the existing Standard Road Pipe Rack that was built in the early 1970s and experienced severe damage due to corrosion at multiple beams, columns, vertical bracing and anchor bolts – all in accordance with the 2013 California Accidental Release Prevention Program Seismic Assessments and the 2016 California Building Code. We also performed voluntary modifications to the lateral-force resisting system.
Solutions
Faced with difficult excavations that required abnormal shoring installation and complex layout, we noticed an unexpected large boulder that presented a hazard to performing the necessary excavation. We helped redesign the structural upgrades and eliminate the hazard of the boulder, keeping the field crews safe during the seismic retrofit.
Project Success
Provided constructibility and value engineering for the retrofits and to the soils engineer.
Project Value
$2 Million
Old Town Utility Corridor (12kV)
Old Town Utility Corridor (12kV)
Lawrence Berkeley National Laboratory
Project Background
Install new 12 kV ductbank and utility corridor for future development. Relocate utilities including main gas line and main compressed air line. Reroute and install new storm drain line.
Scope
- Demolition
- New Retaining Wall Construction
- Underground Utilities
- Site Restoration
- Grading
- Paving
- Masonry
- Mechanical Piping
Challenges
Existing underground utilities locations and the existing main gas line were not shown in design drawings. Compressed air line cut-over and relocation had not been studied and designed based on the limitations of research buildings and other laboratories during the design process. Most of the underground utilities were an unforeseen obstruction during the construction. The project next to the Advance Light Source building could not disturb research by producing any vibration in the vicinity.
Solutions
We redesigned the main gas line and compressed air line relocation to comply with the research and laboratory operations. Because of the Advance Light Source vibration restriction, we completed excavation with nomadic hammer and demolition of the reinforced concrete structure with a concrete processor as a precaution when moving the heavy equipment. We also coordinated with the client to use a jackhammer for demolition/excavation, jumper jack and vibratory roller for backfilling and paving during the ALS maintenance shutdown window.
Project Success
Provided safe and efficient service to a facility that has very unique needs so its research could continue uninterrupted.
Project Value
$5 Million
Long Wharf Sanitary Sewer Replacement
Long Wharf Sanitary Sewer Replacement
Chevron Refinery
Project Background
The existing sewer system was at the end of service (EOS). Requested by client, Chevron, to develop and execute a replacement plan.
Scope
- Demolish the existing 7500LF carbon steel piping system which included:
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- Complete system flush with fresh water
- Insolation, drain down, and blinding
- Saw cut and removal of piping
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- Installation of 3 new septic tanks and pumps which included:
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- Vendor fabrication
- Pre-engineered support system
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- Fabrication and installation of a new 7500LF carbon steel piping system which included:
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- 1000+ welds that required 100% NDE
- 75+ tie-ins into the existing facilities
- 75+ suspended work platforms
- Hand rigging
- Crane and rigging
- Structural steel modifications and installation
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- Provide all QAQC which includes:
- Welder Qualification
- Material MTR’s
- 100% NDE
- Weld mapping
- Strength test of all piping systems
- Flange torque and reports
- As-built drawings
- Provide all management, field supervision, labor, equipment, and materials.
Challenges & Solutions
- Entire project was over water. Nothing in our construction process could enter the bay.
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- GCI developed and executed a site-specific plan to meet this requirement.
- Plan was executed 100% successfully.
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- All flanged connections required double containment.
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- GCI developed the containment system.
- System showed a project cost saving of $250,000
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- Three new septic tanks/pumps were required for this project.
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- GCI developed the installation location and pre-engineered support system.
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- Work had to be planned and completed in conjunction with a fully operational wharf with heavy ship traffic.
Project Success
Logistically difficult project that was completed on time without any disruptions to product deliveries or environment.
Project Value
$4.6 Million
Project Highlights
- Construction was completed without one environmental incident.
- Client requested and relied on GCI’s construction and engineering capabilities to successfully complete this project.
Calol St. Sanitary Sewer Replacement
Calol St. Sanitary Sewer Replacement
Chevron Refinery
Project Background
The project entailed installing approximately 750 LF of HDPE sanitary sewer system on Calol Street for Chevron. The scope included the installation of new sanitary sewer pipelines, manholes, cleanouts, and tie-ins. Calol Street required excavation in multiple phases to install new HPDE sanitary sewer line and manholes.
Scope
- Excavating
- Trenching
- Piping
- Paving
- Underground
- Tie-ins
- Demolition
- Grading
- Sewer System (MHLS)
- Safety: Traffic attendants
Challenges & Solutions
- Multitude of subsurface obstructions which required extra planning to reroute and/or demo obstructions
- Locate and tie-in additional unplanned drain lines
- Tie-into existing 6” force-fed sewer
- Correct flow maintained amongst countless subsurface obstructions encountered due to critical and creative field thinking
Project Success
Completed the 9,200 man hour project with no recordable injuries while working on an operational road. Excavation scope was successfully completed without damaging any underground obstructions.
Project Value
$1.8 Million
Project Highlights
- Installation of 750LF of 12” HDPE sewer line
- Removed 1500 tons of soil during excavation
- Successful tie-in to existing facility sewers and drains
- Multitude of subsurface obstructions (abandoned lines, concrete guy foundations, unmarked duct banks, wood dunnage, etc.)
- Locate and tie-in additional drain lines
- Tie-into existing 6” force-fed sewer
- Working with live lines