LSFO Crude Flexibility Project
LSFO Crude Flexibility Project
Chevron Refinery
Project Background
With an opportunity to increase efficiency and profits, Goebel Construction was tasked by Chevron with the 30 LSFO Crude Flexibility Project. With the new LSFO line, a wider range of products could be moved efficiently to different locations.
Scope
- Earth Moving
- Hydrotesting
- Demo of Pipes & Supports
- Piping Prefabrication
- Pipe Support
- Masonry
- Hot Taps
- Mechanical Pipe Install
Challenges
- The project required excavation through bedrock material.
- The site did not allow access to heavy equipment.
- Hot taps located in areas with limited accessibility require coordinating with multiple contractors.
Solutions
In collaboration with operations management, we were able to generate a new piping and structural support route. The planned route to different locations would open the flexibility of their crude system. The field isometrics gathered during field walks were used by engineering in the final work construction package.
Project Success
Goebel Construction completed the project under budget and a total of 3,850 safely worked man hours. Ensured the project was completed before the end of the year so allocated funding could be utilized. The success and information gathered from the LSFO project led to the wharf capabilities project.
Project Value
$900,000
Project Highlights
- Address: 227 Howard Street, Petaluma CA 94952
- Phone: (707) 763-0088
- Email: info@mailgci.com
Wharf Capabilities Project
Wharf Capabilities Project
CHEVRON REFINERY
Project Background
In order to improve product transportation efficiency to the wharf from various locations. Chevron contracted Goebel Construction to modify its piping to improve efficiency.
Scope
- Pipe Prefabrication
- Pipe Support
- Line Resize
- Addition of Thermal Reliefs
- Pipe Demo
- Pressure Release Device (PRD)
- Supports
- QA/QC Tracking
- Tie-ins to existing lines
- Valve Changes at pump station
Challenges
- Piping Demo Scope of work included working on a hillside with limited accessibility.
- Multiple work-site areas with overhead powerlines
- Scheduled outages left minimal room for error to complete the project on time.
Solutions
We collaborated with operations to map out a new pipeline combined with existing underutilized routes. The field data gathered and the proposed plan was used by engineering for the final work construction package. To save costs, we prefabricated the welds to lower the number of field welds.
Project Success
The project was completed without any reported injuries or environmental incidents for a total of 5,250 man-worked hours. Completed the project by end of the year in order to use allotted funding.
Project Value
$1.1 Million
Project Highlights
- 156 Welds
- 600 ft of pipe demolished
- Utilization of pipe tugging method was safely implemented which resulted in cost savings for the client.
- Foreman forecasted manpower needs to control costs
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
LBNL CMLC Water Line Replacement
LBNL CMLC Water Line Replacement
LAWRENCE BERKELEY NATIONAL LABORATORY
Project Background
LBNL is a multi-program scientific research campus operated by the University of California for the United States Department of Energy (DOE). It is located on a 202-acre parcel of land in Alameda County, California. LBNL introduced multi-infrastructure improvement projects in 2020.
LBNL was seeking for a general contractor or civil contractor to provide site civil underground piping services for the Cement Mortar Lined and Coated (CMLC) Water Line Replacement Project. The project was a collaborative effort between the contractor, engineer of record (GHD), and LBNL. The project consisted of replacing 3,200 feet of old CMLC piping with either ductile iron below grade or steel above grade across the LBNL site.
The schedule was fast-tracked to be able to minimize the impact on the overall campus traffic and laboratories and researchers.
Scope
- Traffic Controls
- Excavation
- Furnish and install new domestic/fire water lines.
- Hydrotest, flush and disinfect new install line per Engineering DWG, Owner Spec and NFPA standard.
- Cut over and replace existing water distribution system with new.
- Backfill and restore site.
- Stockpile material, transfer and dispose excess material.
Challenges
- COVID-19 Pandemic
- Working around live utilities such as 12kV duct bank, Gas line, Sanitary Sewer, and waterline.
- Lead time to procure Piping material due to the pandemic.
- Unforeseen obstruction; existing and live utilities.
- Building and Laboratories schedule, access, and vibration restrictions.
Solutions
To solve these challenges, it was important to: pre-plan, communicate with the client, supplier and subcontractor, monitor the schedule and budget, and provide solutions to the client for any issues encountered.
Project Success
The project was successfully completed with no reported injuries during the 15,849 man-hours worked. The project was finished within the assigned budget ahead of schedule.
Project Value
$5 million
Project Highlights
- Excavation utilizing hand-tools and a vacuum truck.
- Stockpile and dispose excess material.
- Replace existing CMLC domestic/fire water lines with Ductile-Iron-Pipe without interrupting existing feeds to buildings/facilities/arteries.
- Replaced more than 3,200 feet of water line in various sizes
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
Oxidation Pond Closure
Oxidation Pond Closure
Chevron Environmental Management Company
Project Background
Cap and Title 27 closure for a former 66-acre oxidation pond system. At the time, this was the largest active Title 27 Closure project in the United States.
Scope
- Remediation
- Grading
- Paving
- Underground
- Earthmoving
- Soil mixing
Challenges
We needed to solidify and stabilize F037 waste sediments in large inaccessible pond cells to suspend contaminants as well as create usable area for the facility owner. Twenty acres were designed as a “floating cap” where only the top three feet of sediment were stabilized and encapsulated the remaining sediment below.
Solutions
We designed direct pneumatic delivery and placement of Portland Cement and Fly-ash to cells and direct placed soil amendments. This eliminated the need for on-site silo storage and secondary delivery operations of cementitious materials. We used GPS guided equipment to grade and place subgrade and finish surface of aggregate base rock, reducing the personnel required for the task.
Project Success
We completed the closure ahead of schedule and under budget. Our innovative approach resulted in a client cost savings of over $2.5 million and reduced risk exposure.
Project Value
$12 Million
Project Highlights
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
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