- Fluor's scope was roughly one fourth of the overall investment.
- The primary objective was to achieve a 220,000 BPD full-conversion refinery.
- Fluor increased the Madrid Office from 40 to over 700 professionals.
- The project met stringent EU and Spanish environmental requirements.
Project Management and Scope
Fluor provided project management services for the expansion and upgrade of the Repsol Cartagena Refinery in Spain. The role included managing interfaces with licensors and EP contractors, performing Basic Engineering of the “open art” units, ordering long lead equipment, and assisting in the preparation of the project sanction estimate. Fluor was also responsible for engineering, procurement, and construction supervision of offsites, utilities, and revamps, covering roughly one fourth of the overall investment.
Expansion Details
The primary objective was to transform the 60-year-old refinery from a 100,000 BPD distillation capacity to a 220,000 BPD full-conversion refinery capable of processing heavy/sour crudes. This involved adding 20 new process units and 10 utility units, along with extensive modifications to existing units. The expanded refinery is now well-positioned to meet increasing market demand for quality mid-range distillates.
Environmental and Community Impact
The project exceeded goals for hydrogen and energy consumption and met stringent EU and Spanish environmental requirements. It also maximized local labor content, in-country sourcing, and contracting, while implementing world-class safety standards in design and construction. The new refinery's location near an environmentally sensitive area required careful planning to preserve indigenous flora and fauna.
Fluor's Solution
To meet project challenges, Fluor expanded its Madrid Office from 40 to over 700 professionals and assembled an international taskforce, including 100 engineers from the Gliwice Office. Bilingual communications were essential, with 85 percent of the Madrid taskforce fluent in both English and Spanish. Fluor also assisted in obtaining the environmental permit in March 2008 and managed permitting activities, which required a thorough understanding of local codes and regulations.
