Warren Kennedy

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Warren Kennedy
Senior Vice President/Marketing and Sales Director
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P: 816-822-3384
F: 816-822-3416

Phase II Ultra-Low Sulfur Diesel Project

Phase II Ultra-Low Sulfur Diesel Project

Location: Tulsa, Okla.

Client: Sinclair Oil

Completion Date: 2007

Sinclair contracted with Burns & McDonnell to provide engineer-procure-construct (EPC) services for the Phase II Ultra-Low Sulfur Diesel (ULSD) Clean Fuels Program at its Tulsa refinery. To meet new federal fuel regulations, Burns & McDonnell provided a new grassroots naphtha hydrodesulfurization (NHDS) unit and sulfur recovery unit (SRU) in addition to revamping the catalyst reforming unit (CRU) and distillate hydrotreater (HTU) for the inside battery limits (ISBL) portion of the project. To support the ISBL work, Burns & McDonnell provided EPC services for the outside battery limits (OSBL) portion of the program.

  • Engineering
  • Procurement
  • Construction
  • Commissioning (SRU No. 2)
  • Startup (SRU No. 2)

The scope of work included the front-end project planning (FEP) required to define the project, all detailed design work required for construction, procurement services for materials and equipment, and construction services for the NHDS, HTU, SRU and CCR. The OSBL portion of the project included modifications to the existing refinery required to engineer and construct the new naphtha and SRU units, along with the revamps for the CRU and HTU. The ISBL portion of the project included the new grassroots units and equipment required to build the NHDS and SRU No. 2. The project also included modifications to the existing wastewater treatment plant to meet National Emission Standards for Hazardous Air Pollutants benzene requirements.

Burns & McDonnell produced the FEP-3 and definitive cost estimate to secure project funding approval. Assigned to the field during FEP-3 development, the Burns & McDonnell design team worked with operations personnel to collect data for pipe routing and pipe rack modifications, which better defined the off-site work and contributed to the definitive cost estimate for the OSBL work.

Burns & McDonnell employed multiple subcontractors during construction. In this approach, the job was divided into several distinct parts with construction bid packages prepared for each. Multiple subcontractors were used to construct the individual packages, which allowed Burns & McDonnell to hire highly skilled and specific craft labor to construct the project.

The ULSD project will reduce overall air pollution and lessen the environmental impact of vehicles that burn diesel fuel. The economic considerations for Sinclair are quite significant. Due to minimal ULSD supply and high demand, Sinclair realized the premium margins available to refineries that could meet Environmental Protection Agency requirements. Also, the cost reductions achieved by using the multiple-subcontract approach allowed Sinclair to complete other capital projects. 

  • Engineered and constructed new grassroots NHDS unit
  • Constructed new grassroots SRU
  • Purchased and installed new equipment
    • HTU
    • Continuous catalytic reforming (CCR) unit
    • Sulfur plant
      • SRU No. 2
      • Incinerator
      • Tail gas treating unit
      • Sour water stripper revamp
    • NHDS
  • Revamped existing units
    • HTU
    • Catalyst reforming unit
  • Converted existing pneumatic controls for HTU, SRU No. 1 and CRU to distributed controls system
  • Constructed blast-proof control room