ExxonMobil PALA Switch Condenser Replacement Project

Contractor: Industrial Specialty Contractors Inc., Baton Rouge
Location: Baton Rouge
Cost: $4 million
Construction Manager: Jason Templet
Project Managers: James Baldwin & James Mathis
Engineer: ExxonMobil, Baton Rouge

ExxonMobil authorized a two-year, $57.4 million Phthalic Anhydride (PALA) unit upgrade in January 1998. An additional $34.3 million was approved at that time for replacement of 12 switch condensers, related control room and emergency shutdown system upgrades and maintenance turnarounds on two reactors, two furnaces, an 8,000-hp compressor motor and a product finishing area.

ExxonMobil elected to provide engineering services. Industrial Specialty Contractors Inc. was awarded a $4 million, cost-reimbursable contract in June 1999 for electrical and instrumentation work, including installation of process tubing and steam tracing. The job was completed six months later.

An average of 60 ISC associates was at work each day, but the project became far more demanding during the fast-paced turnaround phase, when as many as 220 ISC associates were on site. In just 50 days during this phase, ISC associates recorded more than 66,000 of the project's 86,000 total manhours.

Although the plant continued to operate and much of the work took place in highly congested areas, the project was completed with a perfect safety record, on time and under budget.

The rapid pace and congested work environment meant that cooperation and teamwork would be critical to safety. With that in mind, the project construction team encouraged frequent, active involvement. ISC responded with contributions in all major disciplines, not just those involving ISC's electrical, instrumentation and steam-tracing work.

ISC planning was critical to the success of the project. More than 30 different systems were involved, and shutdowns could not take place concurrently because plant operations continued while the work was underway. ISC solved this problem by scheduling work to coordinate with each system's scheduled down time, and by stressing safety, quality and productivity at every step.