Firewater Line Replacement
Firewater Line Replacement
Chevron Refinery
Project Background
The Firewater Line replacement program was a complex project involving civil and mechanical scopes. The project included the replacement of the existing line, which required extensive excavation, sand backfill, and paving.
Scope
- Project management: set-up, and mobilization.
- Material procurement as shown in specifications and contractor workbook
- Fire-watches
- Traffic control
- Excavation, sand backfill, and paving
- Trench plates
- Layout and weld-bay piping prefabrication
- Field piping fabrication, hydro-testing, installation, and tie-ins
- Coat and wrap underground CS piping and flanges
- Guard post installation
- QAQC and document submittals
- Clean-up and demobilization
Challenges & Solutions
The firewater line project required being set underneath an operational street. Due to the activity of the street, it needed to be open for traffic during non-construction hours.
During the project, we encountered multiple subsurface obstructions. There was also a high-water table that could affect the excavation and installation of the new line.
With great coordination between the team, we were able to restore the roadway daily with trench plates and shoring to keep the road operational after hours.
With multiple obstructions found, we recommended and installed various piping modifications to the firewater line. Due to the high-water table, we ran pumps to pull out excess water to be able to continue work.
Project Success
Successfully completed the project with a recorded 13,500 safe man-hours worked.
Project Value
$1.2 Million
Project Highlights
- Completed 150 carbon steel welds
- Completed 76 HDPE fusion welds
- Installed 475LF of HDPE pipe
- Excavated 270 cu yd of material
- Imported 250 tons of clean rock fill, 110 tons of sand fill and 150 tons of aggregate base rock
- Import level and compact 60 tons of asphaltic concrete paving
- Coordinated excavation and mechanical scope to limit the risk of open dig sites
North Yard Thermal Radiation
North Yard Thermal Radiation
CHEVRON REFINERY
Project Background
Installation of structural supports for thermal shielding panels at catwalk & stairways in Chevron’s RLOP unit. This package includes the installation of support steel and panels. There will be an electrical conduit that will need to be relocated due to the installation of support framing.
Scope
- Place concrete foundations for new staircases and install new steel supports to the existing reactor structure
- Mount new thermal shielding panels to installed structural steel
- Excavate for new staircase foundations
- Place concrete and restore asphaltic concrete
- Drill holes & weld stiffeners to mount new structural steel
- Install new thermal shielding panels
Challenges
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Challenges & Solutions
Working on this project involved several obstacles. An issue working in a location with high visibility due to the elevation. We had to ensure 100% tool tie-off when working at heights, effective implementing of an ePTW system, and dealing with challenging weather conditions like high winds due to high altitude
Project Success
Despite experiencing shipping delays from the manufacturer, we managed to finish the project ahead of schedule. We are proud to report that the project was completed incident and injury free without any dropped objects.
Project Value
$1.6 Million
Project Highlights
- Multiple trade coordination: crane and scaffolding support, electrical, lead/paint abatement, ironworkers
- Drilled 400 holes into existing steel to allow for new support installation
- Installed 100 stiffeners
- Approximately 100LF of structural welding
- Worked with engineering and gave input to resolve multiple fabrication issues with existing steel busts.
Tank-2651
Tank-2651
CHEVRON REFINERY
Project Background
Remove the existing foundation and construct a new T-2651 Foundation at Chevron Refinery.
Scope
- Demo existing tank foundation and over-excavate for placement of structural fill material. Install rebar and forms for the new T-2651 ring wall.
- Layout concrete embedded anchors to exact elevations and specified orientations along the ring wall. Pour tank ring wall. Strip ring wall forms.
- Backfill with sand and structural fill material inside the tank ring wall. Pour concrete cover slab. Wet set leak detection groves during tank slab concrete pour.
- Restored area paving concrete around new tank foundation.
Challenges
- Encountered subsurface firewater lines
- HDPE expands and bubbles with heat from sunlight
Solutions
The encountered fire lines were rerouted by us to make way for the tank foundation. Since HDPE cannot receive sunlight, the tank slab concrete pours began at 12 AM to ensure the HDPE liner was flat and level.
Project Success
The project management team coordinated with procurement to order long-lead items ahead of the execution date to avoid delays. Due to an unplanned grounding, we collaborated with an electrical contractor to meet city inspector requirements without affecting the concrete placement schedule. The project was successfully completed incident and injury free.
Project Value
$400,000
Project Highlights
- As-built existing tank prior to demolition to assist engineering with future construction
- Identified potential issues prior to beginning construction to eliminate time loss during execution.
- Assisted with unplanned emergency scope to fabricate (3) fiberglass pipe spools
FCC Turnaround Project
FCC Turnaround Project
Chevron Refinery
Project Background
During the 4th Quarter of 2020, Goebel Construction executed a Turnaround Event on Chevron’s Fluid Catalytic Cracking (FCC) unit. Considered a Major Turnaround Event by the client, they entrusted Goebel to provide numerous services including mechanical piping, civil construction, and labor support.
Scope
- Detailing and prefabrication of process piping spools
- Temporary piping installation and removal
- Isolation and blinding of unit
- Piping removal and replacement
- Valve changes
- PRD replacement
- Flare piping removal and re-installation
- Cooling tower cleanup
- Import and removal of 3,500 tons of fill for temporary crane pad construction
- Anchor bolt and foundation replacement
- Grout column and flare bases
- Structural steel installation and repair
- Labor ground support
- Safety attendants (fire watch/hole watch)
Crafts Supported
- Address: 227 Howard Street, Petaluma CA 94952
- Phone: (707) 763-0088
- Email: info@mailgci.com
Project Value
$
Project Highlights
- Started and completed during the height of the pandemic
- Pre-turnaround activities: 50,000 hrs.
- Turnaround man-hours, during execution (60-day duration): 100,000 hrs.
- Total man-hours: 150,000
- 465 weld count
- 706 bolt ups
- 7,000 tons earth moved
- 0 recordable injuries
- Project came in under budget and ahead of schedule
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