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

Ultra-Low Sulfur Diesel Project

Ultra-Low Sulfur Diesel Project

Location: Ponca City, Okla.

Client: ConocoPhillips

Completion Date: 2006

ConocoPhillips contracted with Burns & McDonnell to provide engineer-procure-construct (EPC) services for the outside battery limits (OSBL) portion of the ultra-low sulfur diesel (ULSD) project at the Ponca City refinery and construction services for the inside battery limits (ISBL) portion of the project. The OSBL portion of the project included all modifications to the existing refinery that were required to engineer and construct the new ULSD and hydrogen units. The ISBL portion of the project included new grassroots units and equipment required to meet new federal fuel regulations.

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  • Engineering
  • Procurement
  • Construction services

The scope of work included the front-end project planning (FEP) engineering required to define the project, all detailed design work required for construction, procurement services for materials and equipment, and construction services. The project included a new hydrotreater to reduce diesel sulfur, a new sour water stripper unit to expand the capacity for handling the produced sour water, a new hydrogen plant, revamp of two existing hydrotreaters to allow increased capacity and modification of feed streams.

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 field 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 trucks and cars that burn diesel fuel. The economic considerations for ConocoPhillips are quite significant. Burns & McDonnell successfully executed the project during difficult conditions caused by Gulf Coast hurricanes and significant economic expansion in third world countries. These events led to labor availability challenges and price volatility of materials. The project was completed on budget and on schedule, allowing ConocoPhillips to bring the unit on stream at full production rates as required by Environmental Protection Agency (EPA) regulations. Due to low ULSD supply and high demand, ConocoPhillips realized the premium margins available to refineries that could meet the EPA requirements.

  • Revamped two existing hydrotreater units
  • Installed new equipment, including:
    • 25,000-barrel/day diesel hydrotreater
    • 25,000,000-standard cubic feet/day hydrogen unit
    • 100-gallon/minute sour water stripper unit
    • 13.8 kilovolt, inter-refinery transmission line
    • Diesel storage tank