The El Segundo, California turnaround project was conceived by Chevron Products Company to increase the output of gasoline from their El Segundo refinery. To accomplish this, significant modifications to the existing fluid catalytic cracking (FCC) Unit were required. Chevron determined the best approach was to install a new reactor adjacent to the existing unit and to revamp the existing regenerator during a shutdown.

CB&I received contracts for engineering, supply of fabricated materials, project management and field construction on the El Segundo that necessitated a shutdown. The major regenerator modifications required were installation of a new top head and cyclones, installation of a new air grid, and addition of a new spent catalyst nozzle assembly. We designed, fabricated and assembled the elements for the reactor and the regenerator in large pieces, which were then lifted into their final locations with an S-70 stiffleg derrick. Using the derrick allowed an important roadway to remain open during construction. We built a temporary furnace onsite so we could efficiently post-weld heat treat the reactor cone, shell and head assemblies.

During the shutdown, Chevron's inspection workers discovered that a small clad tower (6-ft diameter x 50 ft) within the unit had extensive cracking and needed to be replaced. We designed and erected a stainless steel replacement vessel; the replacement did not affect the overall shutdown schedule. We completed the shutdown in 20 days, three days sooner than expected.