Torrance Refinerty FCCU Electrostatic Precipitator Installation
TIC installed two massive electrostatic precipitators (ESPs) in the fluidized catalytic cracking unit (FCCU) of ExxonMobil’s Torrance Refinery.
Covering 750 acres, the Torrance Refinery processes 155,000 barrels of crude oil per day, to produce 1.8 billion gallons of gasoline annually. The 2009 installation of two new ESPs, weighing in at 1,200 and 1,600 tons respectively, was one of the largest environmental upgrades ever completed at this 1929 refinery. The new ESPs allowed ExxonMobil to drastically reduce emissions—removing 200 pounds of particulate matter and 2,000 pounds of ammonia each day.
Initially contracted to complete civil work, TIC’s scope grew to include the ESP mechanical scope as well. Each ESP, about the size of a 12-story building, was prefabricated by TIC at a remote location within the refinery while other crews excavated, built ESP foundations, and completed duct support foundations. More than 1 million manhours were required— including double shifts and six-day work weeks—to meet ExxonMobil’s timeline. TIC erected the ESP structural steel truss support and completed the tie-in for the duct from the new ESP outlet plenum to the existing SCR. Material quantities included 4,205 cubic yards of concrete; 2,256 tons of structural steel; and 7,588 linear feet of piping.
TIC established a continuous improvement culture which was implemented throughout the whole project.