PROJECT

Rail Access for Renewable Diesel Refinery Conversion

We provided front-end engineering and project development for the conversion of an existing refinery from crude oil processing to processing of renewable feedstocks, renewable diesel and other renewable products. Two of the three phases involved dual rail-served unloading stations.

Conceptual design included investigation of rail layout options to address utility availability and outside battery limits (OSBL) challenges, as well as optimization of railcar unloading spots. The client needed to maintain three days of railcar storage for daily unloading and throughput, while avoiding demolition of critical existing infrastructure.

We leveraged experience with rail unloading as a basis for order of magnitude pricing and used factors and allowances to develop a rough cost range for this quick effort. The team continued to refine the scope and requirements to complete a conceptual phase estimate and basic deliverables. This was closely coordinated with the project team to understand how the project would interface with the client’s plans for the refinery.

The advanced work packaging (AWP) and front-end planning (FEP) included a double-track unloading rack system requiring rail grounding and custom in-track spill containment system to meet state specifications, Union Pacific Railroad (UPRR) and state utility commission roadway diagnostic for a new at-grade crossing, and relocation of railroad signals. The team also coordinated with multiple disciplines to develop a track subsurface drainage system, 34 new or adjusted utility crossing conflicts, and utility trenches through the track section requiring rail direct fixation.

Client

Confidential

Location

United States

Services

Freight Rail

Rail

Renewable Fuels & Chemicals

Industries

Transportation

Oil, Gas & Chemicals

Our team avoided wetlands, floodplains and critical plant infrastructure while providing safety buffer zones to enhance quality and safety during project delivery. Special trackwork design features were incorporated, including multiple parallel crossovers and railcar mover access points. The scope also included the evaluation of existing facilities, integration of multiple licensed units into existing infrastructure, an OSBL revamp, environmental permitting support and wastewater treatment. Extensive revamp of the existing equipment, piping and electrical infrastructure was required to achieve objectives and meet the Class I railroad track clearance envelope and loading standards. The project reduced capital expense through use of existing facilities and infrastructure.

The construction work package included specifications and material take-off to assist the client in obtaining contractor bids. The team continued to provide construction engineering services in reviewing contractor requests for information, submittals, field changes and coordination with the client construction coordinator, surveyor and UPRR field inspector.

Rail improvements were completed in two separate locations within the refinery — one within an existing rail unloading structure to be replaced with eight new unloading spots and over 1,200 feet of track upgrade with three turnouts, and one being completely repurposed to accommodate 28 unloading spots, 20 turnouts/crossovers and over 18,000 feet of new track with a high-volume at-grade crossing.