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ICRI 2013 Project Award Winner
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Award of Merit: Industrial Category

CITGO Refinery Delayed Coker Unit Repairs
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Lemont, Illinois

Submitted by STRUCTURAL

CITGO Refinery

CITGO Petroleum
Corporation, Inc.
Lemont, IL

Project Engineer/

Collins Engineers, Inc.
Chicago, IL

Repair Contractor
Elgin, IL

Material Supplier/

McCann Industries, Inc.
Addison, IL

CITGO Petroleum Corporation, driven by a commitment to safe and efficient operations, planned structural repairs to the sponge coker unit in its Lemont, IL, refinery during 30 days of a scheduled turnaround in the spring of 2012. The refinery manufactures several grades of gasoline, diesel, jet fuel, and high-quality hydrocarbon solvents used in the production of paints, adhesives, and coatings. One of the critical units in its refining operations is the sponge coker unit. Originally constructed in 1968, the coker structure repairs would allow for continued safe operations and the future installation of new upgraded equipment.

To complete the repairs, CITGO required a specialty contractor that could bring together the project management, labor force, equipment, and materials expertise to integrate with their team to safely execute the large scope of work within a short duration turnaround.

The sponge coker required repairs to several areas of the unit. Specifically, four of six heads were removed and replaced; support columns and beams were repaired and strengthened; shotcrete repairs were performed to angled chutes at all six drum locations and the coke pit wall; and the coke pit area was repaired by installing a concrete mud slab, an underdrain system, and a new reinforced concrete slab and transition slab to the existing coke pit ramp.

Working together with their Frontline Safety program, CITGO and the Specialty Contractor formed a unique partnership with one goal in mind: to bring over 200 people to the job site to complete the project with zero safety incidents. With over 67,000 labor-hours worked and a commitment to “safety first,” the project was completed safely, on time, on budget, and will extend the service life of the delayed coker structure for many years to come.

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