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:
      • Complete system flush with fresh water
      • Insolation, drain down, and blinding
      • Saw cut and removal of piping
  • Installation of 3 new septic tanks and pumps which included:
      • Vendor fabrication
      • Pre-engineered support system
  • Fabrication and installation of a new 7500LF carbon steel piping system which included:
      • 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
  • 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.
      • GCI developed and executed a site-specific plan to meet this requirement.
      • Plan was executed 100% successfully.
  • All flanged connections required double containment.
      • GCI developed the containment system.
      • System showed a project cost saving of $250,000
  • Three new septic tanks/pumps were required for this project.
      • GCI developed the installation location and pre-engineered support system.
  • 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.

Long Wharf Sanitary Sewer Crane

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.