Exxon retained CB&I to develop a construction plan for performing two fluid catalytic cracking (FCC) turnarounds at its Baton Rouge Refinery in Baton, Rouge, Louisiana. The upgrades for the two FCC Units (PCLA-2 and PCLA-3) included replacement of the reactors along with modifications to the structure, transfer lines and various other components.

The project was complex because the two units were located in different parts of the refinery, and both were located under regenerators. Furthremore, the PCLA-3 Unit was surrounded by other process units and pipe racks, allowing insufficient area for a crane. Because space was limited, we utilized a 500-ton-capacity stiffleg derrick to lift each of the three 250-ton reactor sections.

Space was not as restricted for the PCLA-2 Unit shutdown. We used a Lampson LTL-1200 crane to assemble the second reactor, which consisted of two large sections and a smaller third section. However, in order to access the PCLA-2 reactor from above, we had to cut the regenerator into three sections and remove it. After we installed the new reactor, we replaced the regenerator and welded the sections back together.

Despite challenges during both FCC Unit shutdowns, we completed the work within schedule and budget.