PROJECT
PROFILES

ExxonMobil Chemical Aromatics
2400-Volt Substation Replacement Project

This project received Louisiana Contractor magazine's 2004 Award for Excellence in the Electrical / Instrumentation category, along with a 2004 ABC Pelican Chapter Award of Excellence.

Baton Rouge, LA - In September of 2003, ExxonMobil Chemical requested lump-sum bids for electrical and instrumentation work to upgrade an aging substation serving the critical aromatics unit at its Baton Rouge facility. The bid package specified that a new 2400-volt substation was to be installed in the same location – an extremely congested area containing numerous high-voltage feeders.

ExxonMobil Chemical awarded ISC a lump-sum contract valued at $275,000 for all labor, supervision, equipment and materials. The project scope included all electrical and civil work necessary to replace the substation, modify the foundation and feeders, install power control systems and then test and cut over the new system with minimal interruptions in plant operations. ISC was also responsible for scheduling, pre-check and review of the testing and commissioning procedures.

The project was organized in five phases. The first phase involved installation of temporary power for two 480-volt switch racks and two 2,400-volt motor starters. Nearby reactors and towers were so close to the substation that simply removing the old equipment presented very serious challenges. Arrangements would have to be made for temporary power, a problem complicated by the six other contractors at work in the plant who relied on the same feeders. Pre-substation electrical and civil work was completed in phase two, which included disconnection and removal of power and control wiring. Also in phase 2, two 3,750 KVA transformers with neutral ground resisters and foundations were removed and the existing foundation was modified to accept the new substation.

The old substation was demolished and removed in phase three. During phase four, ISC associates installed the new substation and two 2,400-volt transformers, two 5,000 KVA transformers, new HVAC/pressurization equipment and three new air conditioning units. Terminations, final power and control connections were completed in phase five, along with testing, commissioning and substation start-up.

When the project was complete on February 19, 2004, nine ISC associates had worked a total of 6,140 hours over the 5-month life of the project, completing the project two days ahead of schedule with a perfect safety record. Testing was successfully completed and the unit was accepted, on budget and three days ahead of schedule – a remarkable accomplishment.

As an integral part of the project construction team, ISC’s participation in the decision-making process was not limited to the electrical and civil aspects of construction. The goal of the project team was to complete a safe and successful project without interruption to the operating facility’s power supply, daily activities, procedures and performance during these modifications.