On a historic day in September 2022, the successful installation of a 2,800-ton cracking furnace at Chevron Phillips Chemical Co.'s Baytown ethylene plant marked a significant milestone. This achievement was the culmination of three years of meticulous planning and collaboration between PCL Industrial Construction Co., led by Robert D. "Danny" Evans Jr., and the project stakeholders. The innovative "supermodule" strategy involved transforming an existing furnace design into modular components that were pre-assembled offsite and transported to their final location. The seamless integration of these modules showcased the team's dedication to safety, efficiency, and cost-effectiveness. Despite numerous challenges, including supply chain disruptions, the project remained on track, demonstrating the effectiveness of this novel approach to industrial construction.
The journey to this moment began in 2019 when the idea of modularizing a complex structure like a cracking furnace was still uncharted territory for many involved. The concept entailed breaking down the furnace into four major assemblies and 17 smaller modules. These components were meticulously crafted offsite and then transported approximately one mile to the Baytown facility. The process required extensive coordination and precise engineering to ensure that all pieces would fit together flawlessly. As the 12-story furnace was lowered into place, its supports aligned perfectly with the pedestals, allowing workers to secure it effortlessly. Evans remarked on the precision of the fit, emphasizing how the careful attention to detail paid off in the end.
Maintaining momentum throughout the project was no small feat. Material shortages and supply chain issues emerged as significant obstacles after the assembly and stacking of modules commenced in September 2021. However, Evans and his team remained undeterred. Their proactive approach ensured that these challenges did not compromise the project's timeline or budget. Mitch Krutilek, formerly Chevron Phillips' general manager for project execution, praised Evans for his commitment to the project, noting his ability to manage resources as if they were his own. Krutilek also highlighted Evans' focus on solutions rather than problems, which kept the project moving forward smoothly.
The success of the Baytown supermodule project is also attributed to the exceptional safety record maintained over nearly 649,000 work hours. Don Abrahamson, project manager for Technip Energies, credited Evans' calm and methodical leadership for keeping the project on track without any injuries or incidents. Abrahamson emphasized that Evans' leadership style helped navigate potential bottlenecks and ensured a smooth workflow. The collaborative spirit among all team members—from senior partners to frontline workers—was another key factor in the project's success. Everyone prioritized the project's best interests over individual agendas, creating a unified effort that made the project truly special.
Looking ahead, Evans and the PCL team are applying lessons learned from the Baytown project to build seven new crackers at another Chevron Phillips Chemical plant. This new endeavor will further refine and expand upon the modular construction techniques pioneered in Baytown. The project stands as a testament to what can be achieved through innovation, teamwork, and unwavering commitment to excellence.