BP Accurately Verifies Quality Control with Advanced Measurement Technology British Petroleum (BP) Toledo is located in Oregon, Ohio on the west end of Lake Erie. This environmentally conscious oil and gas company recently received the award for Outstanding Achievement in Pollution Prevention by reducing carbon dioxide and criteria air pollutant emission by more than 5,500 tons per year.
With 500 full-time employees and 200 contractors working around the clock, BP continually pushes the envelope to increase quality output while reducing emissions by using the ISO 14001 process.
Recently, BP invested approximately $450 million to bring this 160,000 barrel-per-day Oregon plant up to world-class production and environmental standards.
BP’s significant capital investment included the Toledo Reformer 3 Project contracted in early 2011 with KBR, Nooter Construction Company (NCC), and RMF Nooter (RMF) as contractors to fabricate and install several new module assemblies across eight to 10 different locations across the refinery. This involved the construction and installation of large, structural steel modules, which would be carefully lifted and transported into the refinery, Once on site, it was important for the contractors and BP employees assigned to the project to know without a doubt how each module would be seated, bolted, and securely anchored in place.
“Because the modules were so large, we needed to bring them in with a crane,” said Nooter Construction Company Project Engineer Greg Carver. “Using a large crane and moving huge objects always presents some risks on a job. The difference this time was Leica Geosystem’s Total Station — an engineering measurement technology that truly saved us time and greatly reduced onsite safety risks.”
BP Toledo Ohio was one of the first major projects to benefit from Nooter Construction Company’s use of the Total Station 1200+ to determine module specification and fabrication requirements. The TPS1200+ is one of Leica’s most competitive Total Station measurement tools providing today’s most accurate reflector less Engineer’s Data Model [EDM] with the smallest laser dot that measures distances over 1,000 meters. With its combination of extended range, accuracy, laser dot size and measurement time, there was no need for additional instrument setups to reach missing points.
The six modules installed each included eight to 10 columns, measuring approximately 120-feet long and 26-feet wide requiring first-time accuracy and fit by Nooter Engineering. The BP Toledo scope of work dictated that RMF and NCC assemble structural steel modules, install piping, valves, supports, handrails, and grating at an offsite location and then transport and install these modules in the refinery.
The modules had to fit and line-up at the correct coordinates the first time around. There was no room for error and Total Station was the impetus for the error-free installment.
The engineering team at Nooter used Total Station to verify:
1) The anchor bolt alignment and shim packs prior to setting the modules at the offsite location;
2) The elevations and overall dimensions of the module assemblies to ensure correct fabrication prior to transporting into the unit; and
3) That the final location and dimensions met BP Quality Control documentation requirements.
Mike Jaksetic, the construction manager at BP Toledo, confirmed the satisfaction level Total Station engineering technology brought to the maintenance project.
“It [Total Station] is a very efficient and reliable method for gathering the required data to build structures without the need for scaffolding, ladders, or lifting equipment,” Jaksetic said. “It allowed Nooter and KBR to verify plum within tolerance, tie points at correct elevations and coordinates, and crane location to ensure capacities would not be exceeded.”
Harold Jackson, the construction manager at KBR, one of today’s premier engineering, procurement and construction companies, added, “Nooter Construction carefully implemented and put in place solutions to prevent delays to the overall project schedule. This meant it was critical that the team at Nooter verify all dimensions prior to installation to ensure project success.
“While there are always safety concerns when making heavy lifts, we had confidence that RMF and NCC would meet budget, deadlines, and quality control requirements given our past partnership history and using Total Station.”
In the end, RMF and NCC were applauded by the primary contractor KBR and BP for meeting and exceeding fabrication and installment expectations.
Carver noted, “If we had not used Total Station technology it would have been next to impossible to accurately verify the dimensions for BP and KBR given the size and scope of the project, not to mention meet BP Quality Control requirements, which was a major objective.”
The consensus at Nooter: using Total Station makes total business sense.