Coker Modification Project

Cherne was awarded the construction and construction management for this project in a contract directly with Tesoro. Prior to mobilization, Cherne performed constructability planning while resident in the offices of the design engineer. The project required erection of a four-drum Coker Unit with coke handling systems, offsite modifications, and a flare unit, totaling over 2 million manhours. The major challenges of project size and schedule required close coordination with the owner and engineer along with detailed planning to assure alignment of major procurement and subcontract scopes. Adding to the challenge of this project was incorporation of a unit turnaround coinciding with completion of the Coker Unit. The contract scope included the following work which was self-performed by Cherne:

• Civil, Foundations - Instrumentation
• Equipment Erection - Electrical
• Heater Erection (2) - Insulation
• Coke Drum Erection (4)
• Piping

Installation commodities included 40,000 cubic yards of concrete; 250,000 lineal feet of piping; 6,150 tons of steel; 1,140,000 lineal feet of electrical wire and cable and 16,000 lineal feet of cable tray. Close coordination between Cherne and its steel erection subcontractor was essential given the layering of piping and steel required to maintain safe and efficient progress on a congested work site.

In order to complete this massive effort within the challenging time frame specified by the owner, extensive overtime was required. Cherne’s detailed planning efforts included coordination of Saturday, Sunday and extensive night shift work in order to maintain productivity under the extremely challenging time constraint mandated by the schedule. Cherne managed this intense effort to a successful completion in a record 20 months. By coordinating completion of this massive capital project with seamless implementation of the unit turnaround, resounding success was achieved for the entire project.