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Client Large refinery

Location USA

Sectors Petrochemical and refining

The challenge

Increase space, safety – reduce emissions

A large refinery had a turnaround on its Fluid Catalytic Cracking (FCC) reactor coming up, and needed extra power for pre-and post-welding. Yet, based on past experiences with bringing in temporary power, the refinery had some strict criteria. 

First, space was at a premium. Plus, for safety reasons, they didn’t want refueling trucks anywhere near the FCC. Then there were emissions to think about – the last thing they wanted was for generator emissions to trigger the workers’ CO monitors, forcing them to stop work. To resolve these issues, the refinery was open to new ideas.

Project fact file

$1.4 million

Fuel and generator savings

17 MW

Temporary power

18 %

Less emissions than expected

The solution

17 MW of power safely set up 

We thrive on solving power problems like these. There’s always a way forward – you just have to show others that you can get great results by doing things differently. 

In this case, we located 17 MW of power in a vacant space near – but not too close to – the FCC reactor. Cabling ran between the two. We designed the system to increase generator voltage to 4,160V for transport to the FCC, which we then stepped down to 480V for use inside the plant. Saving money, providing total redundancy and peace of mind.

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The impact

Over $1.4 million in savings – better safety, lower emissions

It was pretty clear that we ticked all the criteria from the plant. By placing our temporary power away from the FCC, the turnaround site was safer. Worker CO emissions became a non-issue – total emissions were actually 18 per cent lower than anticipated. And by using fewer generators running at higher efficiencies,we could save on fuel and generator costs. In fact, we clocked up savings of over $1.4 million for the refinery.

“We worked with the plant engineers to help them met municipality safety concerns and see the benefits of locating the power away from the FCC.”

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