Flare Gas Recovery Project—Pennsylvania


Riggs Distler was awarded this project to help our client meet Environmental Protection Agency (EPA) emissions requirements at a refinery in Pennsylvania. Our work involved:

  • Installation of two 25-by-35-foot compressor skids, each weighing 85,000 pounds.
  • Installation of four cooling fin fans, each weighing 65,000 pounds.
  • Installation of a 14-by-60-foot electrical building weighing 80,000 pounds.
  • Installation of 7,000 feet of small- and large-bore piping.
  • Installation of miscellaneous pumps, motors, pipe racks, vessels, and drums.
  • Epoxy grouting, precision leveling, and alignments.

Challenges Overcome

This project involved several logistical and safety challenges, including working alongside an operating gas-producing unit during extreme summer heat. Part of the project included setting large compressor skids, which rerouted flare gas (normally directed to the stack) to the boilers and scrubber. The compressor skids required epoxy grouting, which needed to be installed by large crews according to strict temperature protocols, a challenge given the hot weather.

To maintain appropriate epoxy temperatures while pouring, Riggs Distler shifted our working hours to begin at 4 a.m each day. Our team also built large tents and installed fans for cooling the high volumes of epoxy required for each compressor skid. Our crews were given regular breaks and remained hydrated to ensure safety, and all daily epoxy pours were completed by 10 a.m.

Results Delivered

Riggs Distler’s team persevered through extreme weather, managing all necessary work to ensure EPA compliance by the client’s deadline. Our mechanical team worked closely with Riggs Distler’s electrical team to carefully coordinate all overhead work at the small site, mitigating congestion and keeping the project moving forward smoothly. The skid compressors greatly improved air quality, and all work was completed on time and on budget.