Flint Hills Refinery

Description

Corval Group has provided Flint Hills Resources with maintenance, capital projects and turnaround services since 2004. In 2009, Corval Group earned OSHA VPP status via MN OSHA’s MnSTAR Program for its dedication to World Class Safety.

A recent Flint Hills Refinery project was spread across seven Process Units involving a total of 55 work packages. Work involved a variety of disciplines including demolition, installation of process piping, instrumentation and steam tracing. Support craft included scaffolding, electrical, iron work, crane service, and insulation.

Flint Hills Resources chose Corval Group for its focus on quality, productivity and safety. Much of the work involved difficult-to-reach areas at elevations in excess of 200 ft. Extensive planning was conducted to assure all critical lifts, safety plans, and rescue procedures were in place before work was started.

Working under a compressed schedule and tight budget, Corval Group had over 130 experienced pipefitters on site to meet the project's demanding objectives. The entire project was completed on time and on budget with zero recordable safety incidents.

Project Highlights

• 7 process units involving 55 work packages
• 130 pipefitters on site
• Precision work done at elevations up to 230'
• Safety: zero recordable, zero first aid
• Quality: 96.5% Weld acceptance
• Productivity; On plan and schedule

One high profile aspect of the project involved the demolition and reinstallation of the flare tip at a 230' elevation. All rigging was set in place utilizing a 250 ton crane. The first pick was estimated at 2.75 tons. The second pick was estimated at 6.5 tons. Work on the flare tip needed to be closely coordinated with support craft to build scaffolding off existing platforms so all trades could work at the correct heights safely and efficiently.