Hydrogen Gas Plant—Delaware

March 2019-Spring 2020

Riggs Distler is providing extensive heavy civil, mechanical, and instrumentation services in support of the construction of a hydrogen gas plant in Delaware. The plant will be an integral part of the refining process. This project is ongoing and involves a total of 75 Riggs Distler employees.

Our work includes:

Civil Scope

  • Installation of E&S controls, concrete foundations, stormwater and drainage systems, fire water system, and grounding for the new plant.
  • Performing excavations and structural backfilling.
  • Placing concrete with anchor-bolt embeds set to precision locations. 
  • Work strictly adhered to American Concrete Institute, American National Standards Institute, and Riggs Distler’s safety standards.
  • Sitewide scaffolding erection.

Mechanical Scope

  • Setting all plant equipment, including drums, coolers, pipe racks, vessels, pumps, and skids.
  • Assembly of large equipment, including the cooling tower, flare stack, and Reformer Heater, the largest and most important unit in the plant.
  • Setting, alignment, and grouting of all rotating equipment including hydrogen compressor
  • Installation of all piping systems, steel and supports.
  • Installation of all instrumentation and controls.
  • Hydrostatic testing, pre-commissioning, and commissioning of the entire plant.

Project Management (Subcontractors)

  • Pipe and equipment insulation.
  • Refractory installation, block and cast-in-place.
  • Structural steel erection.
  • NDE, including X-Ray, PT and PWHT.
  • Field machining and piping.
  • Painting (field touch-up)

Challenges Overcome

Careful project scheduling and coordination were key concerns from the outset. The project adhered to an accelerated schedule with built-in incentives for early completion and penalties for late completion. To meet the schedule, Riggs Distler carefully organized the work of multiple subcontractors, settled jurisdictional disputes, and constantly coordinated with the client and our project teams. Both our Heavy Civil and Mechanical teams implemented a number of new construction techniques that improved efficiency and speed.

Delayed equipment deliveries also had an impact on the projects schedule. Orders of steel and other equipment were not provided at the correct specifications, and instead required modifications in order to fit their use. The client requested significant amounts of overtime to support these equipment delays, along with multiple requests for out-of-scope rework, and Riggs Distler swiftly accommodated all requests.

In order to manage these requests, our managers developed a system to efficiently track costs by synchronizing our time-tracking tools with the Time and Materials ticketing process, allowing the client to view project hours, expenditures, and invoices in real time. Riggs Distler’s ability to draw on expert staff resources at all levels allowed us to react quickly, keep the project properly staffed, and remain on schedule despite numerous delays.

Results Delivered

Once complete, the new hydrogen plant will reduce the amount of sulfur generated by the combustion of crude oil at the refinery, allowing the client to operate cleanly and meet global limits for sulfur production instituted by the International Maritime Organization. Through careful tracking and project management, Riggs Distler worked hand-in-hand with the client to cut costs and save time without sacrificing worksite safety or the quality of our work. Riggs Distler’s turnkey, multidisciplinary approach allowed us to realize efficiencies across the project scope that would not have been possible for other companies to accomplish.