FLUOR CONSTRUCTORS

SM

Winter2001 InSide
ahead of us and a tremendous opportunity for growth. We must continue to have a strong presence in the Canadian oil sands industry. We must continue to build upon current working relationships. And we must continue to show why we are a leader in constructing some of the largest petrochemical facilities in North America. Realizing our potential also means celebrating our past. In this issue of OnSite, we feature a construction yearbook, a look back at the projects from last year and a look ahead to the projects in 2001. But knowing thyself also means improving upon our current processes and programs. The Construction Technology group and the Global Knowledge Community are two of the exciting initiatives weve recently launched. Both will allow us to capitalize on existing construction knowledge within our organization. But these changes can only get us so far. It takes people at all levels of our organization to make Fluor Constructors a world class team. We must exhibit strong leadership on our projects. We must attract and retain new members. And we must continue to appreciate and recognize our current members both in the home office and in the field. And that advice is far from ancient.

2 3 6 14 15 16

On Construction Next Stop: Saudi Arabia On Safety Safety News On Projects Construction Yearbook On the Leading Edge Construction Comes to a Screen Near You: Fluors Global Construction Community On Productivity The Power of 1.0 On People Introducing Our Technology Team On the Cover Changing Skyline On Personal Best People Who Are Making a Difference at Fluor

Getting Back to Basics

In ancient times, the Greeks spoke of the Oracle at Delphi. Known for giving sound, but cryptic advice, the Oracle became a legendary source for dispensing thought-provoking messages like, know thyself. At Fluor Corporation, we believe the Oracles ancient advice makes as much sense today as it did then. Knowing thyself means re-examining our organization and understanding where our roots lie: in construction. Todays Fluor started out as a small construction company in Santa Ana, California, in the early 1900s. Construction was an important part of our past. Construction will be an important part of our future. As such, Fluor Corporation is undergoing change. I am honoured to be part of that change as the newly appointed president of Fluor Constructors International, Inc. This is an exciting time for construction in our organization and I look forward to being part of the positive changes that will unfold in the months and years to come. Some may see change as just that, change. I see it as an opportunity, particularly for Fluor Constructors in Canada. We have a challenging year

17 22

OnSite

is published quarterly for members of Fluor Constructors in Canada. Please send your comments and ideas to amanda.condie@fluor.com or phone 403.537.4090. Amanda Condie Editor: Graphics: Daniel McAloney
Copyright 2001 Fluor Corporation All Rights Reserved Fluor Constructors is a registered service mark of Fluor Corporation

president Fluor Constructors International, Inc.

Rick Robinson

A status report on current projects for Canada

Next Stop: Saudi Arabia
Excerpt taken from the Fluor Canadian Newsletter. Jane Hurly, HurlyWorks Inc.

OnConstruction

SHELL UPGRADER

Fluors role

Fluors elite task force, culled almost entirely from Calgarys senior ranks, will peak at 40 in mid-2001, and is headed by project director, John Richardson from When Calgary was awarded a contract Fluors Houston office. Project manager, by Saudi International Petrochemical Jim Brittain and engineering/process Company (SIPC) early manager, Abdul Harji, last year to provide will assist him. basic engineering, Fluor is providing front-end engineering project management serOnce the and overall program vices for the project. Afconstruction management services ter basic and front end activities for a US$800 million engineering is complete commence, we petrochemicalproduction by mid 2001, lump sum facility in Al Jubail, enturn key (LSTK) bid will assemble a gineering manager packages will be preconstruction Abdul Harji felt justipared by Fluor for the management fied in celebrating. He four facilities and be put team in Saudi had good reason. out for tender to internaArabia. One of the strategic tional bidders who speobjectives for FY2000 cialize in LSTK projects. Abdul Harji was to win more interFluor and SIPC project engineering/process national work. This is personnel will jointly manager proof of that paying evaluate the bids and off, he says. This make recommendations award also begins the to the executive managelong journey to satisfy one of our ment of SIPC. visions established at the recent Contractors will be selected for each of FY2001 Canadian strategy planning the four facilities. session to become a recognized Staff from our office will mobilize in the international EPC contractor in the offices of the individual LSTK contracchemical industry. tors to work with them through the engineering and procurement phase, says The project Harji. Once the construction activities The SIPC project will use natural gas, commence, we will assemble a construcbutane, and ethylene, which are readily tion management team in Saudi Arabia. accessible feedstocks in Saudi Arabia, He sees this as a golden opportunity to and inexpensive to purchase, as raw show the world Fluors colours. materials to make value added products This is a one-of-a-kind opportunity to butanediol (BDO), methanol, acetic acid project our expertise in the business of and vinyl acetate monomer (VAM). petrochemicals on a world stage. This is Products are slated for markets in the a foothold in Saudi Arabia. We cannot Far East and in Europe. afford not to win these.

Ft. Saskatchewan, Alberta Construction Manager: Gene Testolin Construction progress stands at 12%. Overall sitework and civil stand at 38%, while 40% of the concrete is complete. Structural steel and piperack setting in some units have commenced. The second shipment of reactors and heavy wall vessels has arrived. Mechanical completion is targeted for September 2002.

SHELL MUSKEG RIVER

Ft. McMurray, Alberta Construction Manager: Gary Lothamer Construction progress stands at 25% complete with engineering at 62% complete. The first six of 112 pipeway modules have arrived on site three weeks ahead of schedule. They are set in place. Mechanical completion is scheduled for mid 2002.

SUNCOR MILLENNIUM

Ft. McMurray, Alberta Construction Manager: Robbie Barron Construction progress stands at 63%. All modules are complete and structural steel is 85% complete. Current focus is on instrumentation, electrical and piping work with 50% of the piping complete. Hydrotesting has started. Mechanical completion is scheduled for October 2001.

TRANSCANADA MIDSTREAM

Ft. McMurray, Alberta E&I Superintendent: Doug Knisely Present scope of work for Fluor Constructors includes Electrical and Instrumentation. Temporary power has been completed and insulation of cable tray has begun. Electrical heat tracing is 75% complete at the module yard.
2

OnSafety

modsquad

Our Supervisory Team Plays a Key Role in Our Modified Work Program
When it comes to Fluor Constructors Modified Work Program, management, supervision, health center personnel and injured employees each has responsibilities. As a supervisor, here is what you need to know Investigate the illness or injury Refer and accompany the employee to the site Health centre immediately after a report of an injury or illness K Complete an incident investigation report K Participate in the rehabilitation planning and implementation process K Set an example for the worksite
K K

BBSM Observer Team, Muskeg River Oil Sands project Left to right. Doug Gillman, ProRhey Depro, Martin Haghey, Peter Jenkins, Chad Mackey, Edouard Vachon, Carl Ekeberg, Dorothy Lutzak, Dave Stout, James Gill, Bradley Dodge, Bill Westergard, Jozo Vistica, Armand Desrochers, Otis Ross, Wade Carson, Sandy Duncan, Wayne Williams and Doug Thornton

Building the Momentum of BBSM

The Muskeg River mine site BehaviourBased Safety Management (BBSM) Program, championed by Gary Lothamer, deputy project director, construction, is gaining momentum as more craft arrive on site. They tend to like it, says Doug Gillman, Behaviour-Based Safety coordinator at Muskeg River. Formed in November 1999, the BBSM team meets every two weeks to examine the data collected during their observations. Gillman says, so far, the top safety concern has been the improper use of safety glasses. Its concurrent with weather conditions, he says, adding that the tendency is to remove the glasses when they fog up. In addition to the traditional BBSM Program, this site recognizes and rewards craft exhibiting safe behaviours during the BBSM observation walks. The names of those safe people are submitted into a weekly draw for a silver dollar award. About 98% of the guys out here exhibit safe behaviour, and we dont say thanks. This program is aimed at recognizing their efforts day in and day out.

Why is the Modified Work Program important? Mandatory on all Fluor Constructors projects K Contributes to the employees overall health and well being K Lowers our Workers Compensation Board rate which gives us an edge in bidding future jobs
K

Its a real win-win, says Robbie Styba, senior corporate occupational health nurse. For Fluor and the project owner, the employee who performs modified work during recouperation from a work-related injury contributes to higher productivity and lower costs. For workers, the program ensures uninterrupted pay as well as a safe and timely return to the jobsite. But remember, the assigned Modified Work Program duties must be meaningful to the employee and appropriate to his or her restrictions.

Profile of an On-Site WCB Coordinator....Jeannie Buckles

Name: Position: Education: Experience:
Jeannie Buckles Workers Compensation Board coordinator on the Suncor Millennium project in Fort McMurray, Alberta I am a nurse in independent practice and am currently enrolled in the Occupational Health Nursing Program at Grant MacEwan Community College in Edmonton, Alberta. I have been a nurse working in Fort McMurray in the critical care areas like emergency, air medivac, intensive care, and the operating room, for over 20 years. I worked as the site occupational health nurse on the Syncrude Canada Ltd., Aurora Mine Construction project. As WCB coordinator, my role is to understand the issues that confront the injured worker and to help him, or her, understand the work-return options available. I am also responsible for workreturn planning and helping workers evaluate worksite modifications that minimize work disruption and increase productivity. What has been most interesting so far is the size and scale of the project and the friendliness of the people working with me.

Role:

Left to right. Jeannie Buckles, WCB coordinator; Bob Kelly, craftsman; and Robbie Barron, construction manager

Project highlights:

5=BAJO

Q: A:

When was the hardhart invented? 1933. Construction hardhats were first invented specifically for those workers building the Hoover Dam. The Hoover Dam spans the Colorado (source: www.FunTrivia.com) River between Arizona and Nevada.

Tom Eggleston, construction director; Gene Testolin, project construction manager; and Jimmy Boulet, Primary Process Unit (PPU) construction manager work with the PPU Safety team to develop a systematic safety management plan.
PPU Focus Inspection Matrix January to March 2001 Schedule
Unit Areas

Shell Upgraders Safety Team Focuses on Big Picture

Shows % Compliance

Auditors Initials

A section of the PPU safety chart

The safety management plan targets two key result areas (KRAs) based on the site safety manual. The first KRA addresses line management responsibilities for the foreman up through the construction manager. The second KRA addresses high-risk safety procedures that craft follow everyday. Both KRAs are easily communicated and measured via wall-sized grids. The challenge, says Jimmy Boulet, is to communicate performance expectations and to provide timely support. That grid helps us keep our eye on the bigger picture, says Mike Donovan, PPU safety manager. We want to see trends before an incident occurs so we can continually improve. I believe this approach will provide timely support to our supervisory team, adds Boulet. They can make the necessary changes and protect our people from getting hurt.
4

Construction Yearbook

OnProjects

he year 2000 has been a good one for Fluor Constructors in

Canada. With those projects behind us and more on the horizon, 2001 looks just as promising. Heres a look back at our members and the projects that made last year a memorable one.
6

Some of the LP7 team members. Left to right. Mike Stephens, construction director; Ed Cade, construction manager; a boilermaker craftsman, Chester Dodd, area manager; Cor Ooijkaas, area manager; Dave Gallina, safety manager; Bob Thompson, Performance Plus coordinator

Above. The polyethylene reactors on LP7 Right. Early construction on the project

ThePlant
UNION CARBIDE LP7 - PRENTISS, AB
Client: CM: Craft peak: Hours: Concrete: Pipe Spools: Pipe: Cable: Piles: Heaviest vessel:
all numbers are approximate

Union Carbide Mike Stephens 1,200 3.3 million hours 17,461 cu. yd (13,350 cu. m) 12,083 65,248 feet (49,884 m) 1.9 million linear feet (597,426 m) 1,360 vacuum tower T-801, 102 tons (92.5 tonnes)

Union Carbide Canadas (UCC) low-pressure polyethylene pellet plant, LP7, produces 1.3 billion pounds of polyethylene pellets per year. Fed by ethylene from NOVA Chemicals E3 Joffre plant (see following page), the project represents UCCs largest polyethylene plant worldwide. Polyethylene, more commonly known as plastic, is used to make a wide variety of packaging materials and consumer products.

TheProject
Mike Stephens, construction director and construction manager on LP7, was most impressed with this projects outstanding safety record and the excellent collaboration amongst the project team. Field staff, craft, engineering and client...worked as an exceptionally cohesive unit and should be congratulated, Stephens added. In a difficult set of circumstances, they got things done.

The C2Splitter, the tallest and heaviest of the five major vessel lifts on E3.

Just a few of the faces on the E3 team

12 out of the 32 piperack modules

NOVA E3 - JOFFRE, AB
Client: CM: Craft peak: Hours: Concrete: Pipe Spools: Pipe: Cable: Piles: Heaviest vessel:
all numbers are approximate

ThePlant
NOVA Chemicals, one of North Americas largest petrochemical producing facilities, is located near the rural hamlet of Joffre, a short distance east of Red Deer, Alberta. Their new E3 facility at the Joffre site produces 2.81 billion pounds of ethylene annually, making it the largest ethylene plant in the world. The E3 plant is the first of four NOVA Chemical projects planned over the next decade.

NOVA Chemicals Gus Dontanville 2,100 6.3 million hours 50,000 cu. yd (38,250 cu. m) 16,000 241,800 2 million linear feet (610, 000 m) 3,000 C2 Splitter, 550 tons (499 tonnes)

TheProject
Owen Jones, general superintendent on E3, felt that the project was memorable for many reasons. The quantities of steel, modules, pipe, and cable were double any other project he had been involved with. Although achieving every milestone was an accomplishment, Jones said that achieving mechanical completion by June 2000 was the most memorable. He also was impressed by the way the job came together despite some late deliveries. Both craft and staff members worked hard to meet those dates. The combined team effort of home and field staff and the support of unionized craft made this project successful. (Everyones support) was greatly appreciated, added Jones. There was harmony among the craft themselves. They worked well together.
8

SHELL MEG FT SASKATCHEWAN, AB

Client: CM: Craft peak: Hours: Concrete: Pipe Spools: Pipe: Cable:

Offloading a MEG-destined vessel in Vancouver, BC

SHELL Chemicals Canada Ltd. Jimmy Boulet 1,100 2.5 million hours 11,772 cu. yd (9,000 cu. m) 7,464 187,476 feet (57,140m) 1.2 million linear feet (357,000 m) 1,609 The reactor, 750 tons (680 tonnes)
View of the MEG project in November 1999

Piles: Heaviest vessel:

all numbers are approximate

ThePlant
Owned and operated by Shell Chemicals Canada Ltd., the mono-ethylene glycol (MEG) production unit is located at Scotford, Strathcona County, Alberta, next to an existing styrene monomer plant. MEG is one of the largest single-train ethylene glycol manufacturing facilities in the world. The unit relies on ethylene from the NOVA E3 facility (see page 8) about 200 km away in Joffre, Alberta. The MEG facility produces 400,000 tonnes per year of monoethylene glycol, a chemical intermediate used in the manufacture of polyester fibres, films, PET resins for recyclable drink containers, and antifreeze.

TheProject
Jimmy Boulet, construction director on Shell MEG, said the key to this projects success was its strong team effort, despite some of the challenges. For a project of this size, there were a lot of different entities, he said. Its always a challenge when you have multiple companies involved. In addition to the alliance between the engineering firms of Fluor and Colt, personnel represented Shell divisions in Canada, the United States and The Netherlands. Everybody, including the building trades, consciously worked to make it a successful project. And it showed in the resultsa project constructed on time and under budget.

Aerial view

PDS model of the plant

ThePlant
Irving Oil Ltd.s King of Cats project is the single largest private sector investment in New Brunswicks history. In fact, it is one of the largest refinery upgrade projects in North America. Before the upgrade, about one third of each barrel of crude processed was too heavy to turn into lighter products like gasoline. The new Resid Cat allows the longer molecules of heavier material to be broken down so that a greater percentage of lighter, higher quality fuels can be extracted. The new Resid Cat produces 70,000 barrels per day and significantly increases the refinerys efficiency.

Ian Mac McVittie, Fluor vice president, construction, and project construction manager; Warren MacKenzie, Irving Oil Ltd; Bill Verbeek, RFCCU construction manager

TheProject
Ian Mac McVittie, Fluor vice president, construction, and project construction manager, said he was pleased at how quickly the project came together. The crude unit took 21 months after release of detailed engineering, and the cat cracker took 23 months after detailed engineering. McVittie added that King of Cats was memorable for other reasons. Working with a privately owned company as client and using local expertise made the project unique. We picked up a number of local people who now have joined our other projects in Alberta, he said. I want to thank them and the entire Fluor team for their efforts.

IRVING OIL RUP - SAINT JOHN, NB

Client: CM: Craft peak: Hours: Concrete: Pipe Spools: Pipe:

Irving Oil Ltd. Ian Mac McVittie 3,500 6.9 million hours 55,000 cu. yd (42,075 cu. m)

35,000 770,000 feet (234,850 m) 3.5 million linear feet (1.07 million m) Cable: 6,950 Piles: Heaviest vessel: 2nd stage reactor regen vessel, 580 tons (526 tonnes)

all numbers are an approximate

10

Millennium site looking west from the top of the derrick Inset. Robbie Barron, construction manager

Site Innovation
Frank Hopple and the site Local 488 members developed a procedure for welding stainless steel pipe that eliminated the need to purge the pipe of oxygen. Their new system used Lincolns Surface Tension Transfer (STT) system. STT operates much like a MIG welder by delivering a shielding gas along with a wire fed from the welding head. Working from previous trials, Local 488 members Roy Anderson and JJ Smith experimented with a mixture of gases and wires. This experiment led to a tri-mix of 90% helium, 7 1/2% argon and 2 1/2% CO2. When combined with Lincoln Blue Max wire, these gases returned consistently good results. This new weld procedure was approved June 6, 2000. As of the fall, over 1500 diameter inches had been done without a single repair.

SUNCOR MILLENNIUM- FORT MCMURRAY, AB

Client: CM: Craft peak: Hours: Concrete: Pipe Spools:

Suncor Energy Robbie Barron unavailable 10.7 million hours* 115,800 cu.yds (88,587 cu.m) 34,357

Pipe: Cable: Piles:

550,639 feet (167,945 m) 8.8 million linear feet (2, 693,760 m) 8,196

Heaviest coker drum, vessel: 415 tons (376.4 tonnes)

*As of January 2001 all other numbers are approximate and as of December 2000

ThePlant
Suncor Energys Project Millennium is designed to expand the companys oil sands mining and processing capacity to 225,000 barrels of oil per day in the year 2002. This will more than double 1999 production. The biggest growth project in Suncors history, this CDN$2.8 billion project involves further development of the Steepbank Mine, expansion of the extraction and upgrading plants, and increased supplies of steam, water and electricity. Its construction, which began in April 1999, will be completed in mid-2001.

Robbie Barron, construction manager, says he is pleased with the way the job is progressing. At 60% completion, construction has entered a new phase. Currently its going very well. Apart from the weather, everything is in our favour. We are heavily into piping and electrical, explains Barron. As they approach peak manpower, Barron advises that its important to maintain a safe work site and pay attention to sequencing and scheduling. Progressing from bulk installation to systems, we must sequence the work correctly to meet the clients need.

TheProject

DUPONT BCF 93 III KINGSTON, ON DUPONT Canada Ed Cade Craft peak: 215 202,000 Hours: 2100 cu. yds. Concrete: (1606.5 cu. m)
Client: CM: Pipe Spools: Pipe: Cable: Piles: Heaviest vessel:

ThePlant
BCF 93 III is a nylon spinning facility which produces carpet yarn from nylon pellets. This is the third facility of this type constructed by Fluor for DuPont at their Kingston, Ontario, site. This facility houses four new spinning machine units that can manufacture 40 million pounds of bulk continuous filament.

4,000 39,000 feet (11,895 m) 57,778 linear feet (17,622 m) 107 pack heaters 13 tons (11.8 tonnes)

TheProject
The project involved the construction of a 80,000 square-foot building with an exterior mezzanine for progress air equipment. Large trusses on the fourth floor created clear spans for the spinning equipment and supported the tower which housed the flake system. The largest of these trusses weighed about 17 tons. Inside the building, 10 vessels were installed, the largest being the flake conditioner. As construction on the project progressed, DuPont personnel worked alongside the craft installing the spinning machine components. We had great customer repoire working with Dupont management and engineering, said Ed Cade, construction manager. It was nice to be able to accommodate them, and they, in turn, accomodated us. Cade also admitted that this strong relationship would not have been possible without Fluors core team in Kingston. Mike Donnelly and the engineering group did the majority of their work with DuPont. I think they were the reason why we were brought in to construct this facility, commended Cade.

Above. The Process Handling Units Below. The Diphenol, Diphenol Oxide room and handling

all numbers are approximate

12

Offloading the reactors at the Upgrader

Photos courtesy of Shell Canada Limited

The Year Ahead

Making a Presence in Oil Sands Country

Fluor Constructors is presently involved with the Athabasca Oil Sands Downstream Project, a major expansion program consisting of three segments: the Muskeg River Project near Fort McMurray, Alberta (Upstream); Corridor Pipeline (Midstream); and the Scotford Upgrader near Fort Saskatchewan, Alberta (Downstream). The Muskeg River Mine will produce diluted Athabasca bitumen from a site 70 km north of Fort McMurray. Diluted bitumen from the mine will be transported via pipeline to the upgrader site at Scotford. Recovered diluent will be transferred back to the mine for further product use. Upon completion, the Mine will produce 155,000 barrels per day of bitumen, which, after upgrading, will provide refiners with transport fuel feedstock.
One of the Primary Separator Cells (PSCs) at the Muskeg River site.

ontheleadingedge
Whats Now

Construction Comes to Canadian Television

Tune in to the Discovery Channel in February, and catch a glimpse at how Virtual Reality technology is changing Fluors business in mining. An upcoming episode in the series Frontiers Of Construction features members successfully using VR technology on the Morenci Mine project in Arizona. The Morenci Mine segment really shows the application of VR in a concrete and tangible way. Its terrific, says David Langer, producer of the series. In its second season, Frontiers Of Construction airs on Discovery Canada, Discovery Europe, and in Asia.

Shortsighted thinking and technology...

I think there is a world market for maybe five computers.

Thomas Watson, Chairman of IBM - 1943
Source: internet

Whats New

Fluor Launches Global Construction Community

Program information
Virtual Engineering: When charts and blueprints arent enough, engineers turn to Virtual Reality simulations for answers. Simulations allow engineers to test their plans before time and money is spent on construction. This episode airs at the following times on the Discovery Channel: Mon, Feb 12 at 10:00 PM ET Tue, Feb 13 at 3:00 AM ET Tue, Feb 13 at 4:00 PM ET Sun, Feb 18 at 3:00 PM ET
Episodes may be re-run at a later date.

For more infomation visit www.exn.ca

Online Site Allows Members to Build, Share and Apply Knowledge Canadian construction knowledge. sites, since its launch in September. Thats what Fluor Corporations new The information on this site gives us an online Knowledge Community needs. advantage that our competitors do not In todays competitive marketplace, the have, explains Barry Sankey, construcknowledge and experience of its mem- tion technology manager. bers gives Fluor Corporation a distinct We all have to take ownership, advises advantage in winning and completing Hank Vanderland, construction construction projects. But how can automation manager. If you want to get Fluors knowledge-rich specialists some good stuff out of it, you have to around the globe share their informa- put some good stuff into it. tion and assist the field in quickly So what can Knowledge Management solving critical problems? contribute to construction? This new Web-based Global Construc- Quick access to valuable knowledge tion Community provides the answer. An efficient method for capturing, Much more than a database, this online storing and sharing knowledge. Community encourages professional A link for global communication and collaboration, builds our global knowl- collaboration. edge, hosts online forums to answer Innovative approaches to how we work technical questions, shares success A vehicle for learning. stories and develops the professional experience of members. Since early 2000, Fluor has been establishing online professional communities, each focused on a core operation like For more information on the engineering and Global Construction Knowledge scheduling. The Community, contact Barry Global ConstrucSankey or Hank Vanderland at tion Community 403.537.4600 has been among the most popular
14

OnProductivity

power
of
Only in Canada, EH?

the

Does your PF need a boost?

1.0
2.0

Try these expert tips to maximize your productivity & performance

When the Thermometer Drops, So Can Productivity

Working in the Canadian construction industry means dealing with the cold Canadian winters. While weve learned to ward off the wet stuff by wearing
1.0

proper clothing and having temporary shelters near our work areas, cold weather can still have an effect on productivity. Table 2.0 shows the combined effect of humidity (R.H.) and temperature on productivity. This table was developed by the National Electrical Contractors Association. However, it can be used as a guide to show the effects of weather on productivity for most construction tasks. Thinking of working in warmer climates? Productivity problems can still occur. Heat related injuries like sunburn, cramps, exhaustion and heat stroke can happen at temperatures above 49 C at 10% humidity and 31C at 100% humidity. Relationship of temperature and humidity to productivity
minus

Work efficiency in cold weather Loss in Efficiency (%) Gross Skills Fine Skills 0 0 0 5 10 20 25 35 15 20 35 50 60 80 90-95* ----

Temp C 4 -2 -7 -13 -18 -23 -28 -34

R.H. 90 80 70 60 50 40 30 20 56 57 59 60 61 62 62 62 71 73 75 76 77 78 78 78

Temperature C
7 1 4 10 16 21 27 32 38 43

23 18 12

* probably cannot work

82 84 86 87 88 88 88 88

89 91 93 94 94 94 94 94

93 95 97 98 98 98 98 98

96 98 99 100 100 100 100 100

98 100 100 100 100 100 100 100

98 100 100 100 100 100 100 100

96 98 99 100 100 100 100 100

93 95 97 98 99 99 99 99

84 87 90 93 94 94 93 93

57 68 76 80 82 84 83 82

0 15 50 57 60 63 62 61

Source: Productivity in Construction, Institute for Research in Construction, National Research Council Canada

ONE-MINUTE

IDEAS
Building Team Skills
Some 85% of ceos in 907 fast growing companies consult team members before making business decisions. Message? No project, no area, no crew can thrive on just one persons skills.
Kauffman Center for Entrepreneurial Leadership and Ernst & Young, cited in Working Women, MacDonald Communications Corp, 135 W. 50th St., New York, NY 10020 as printed in Communication Briefings

Be a Trouble Shooter
When you run into a problem, try to think of at least two solutions before you take the problem to your supervisor. It shows that youre a thinker and a problemsolver, as well as a doer.
You Can Find More Time For Yourself Every Day, by Stephanie Culp, Betterway Books, 1507 Dana Avel, Cincinnati, OH 45207 as printed in Communication Briefings

Four Questions
Every once in a while, ask yourself these questions: What are we doing? What should we be doing? What should we be doing next? What should we not be doing?
Bill New, CEO, Natus Medical, writing in from 36,000 feet..., 6436 City West Pkwy., Ste. 440, Minneapolis, MN 55344 as printed in Communication Briefings

Introducing Our

OnPeople

Construction Technology
One stop shopping. Thats how Barry Sankey describes the new Construction Technology team at Fluor Constructors in Canada. The team, which formed in December of last year, will enhance field productivity by using a number of in-house programs. Weve always had these tools available, but there was no central focus, he explains. This group will take broader focus. Some of the tools that will fall under Construction Technology include the Construction Knowledge Community; Constructability, construction input at the front end of a project; Performance Plus, a field-focused productivity program; and our suite of automation tools, like InVision, a graphic data tool, and MileMarker, a progress tool. It takes a large amount of data to execute a construction project, says Sankey. One objective of the group is to use automation tools to improve work processes by leveraging information from existing engineering data. Training and access to the tools will also be part of the groups focus. (The field) can look to our group for assistance in implementing the technology and automation tools. Hank Vanderland agrees. He says the difficulty is not the lack of information out there, but the difficulty in managing, accessing and using the right information With all these tools and databases, we must work as team players, more than ever before. Canada is not alone in establishing such a team. Fluors Greenville, South Carolina, office in the United States was the first to put together such a team. But the difference, says Sankey, is that this team is tailored to the Canadian construction environment.

Team

Barry Sankey
Construction technology manager 11 years of Fluor experience After nine years in the field, Barry returns to the Calgary office to launch Fluor Constructors Construction Technology team. Field personnel may recognize Barry from the Irving Oil King of Cats project in Saint John, NB, where he was chief field engineer.

Hank Vanderland
Construction automation manager 14 years of Fluor experience Hank joined Fluor Constructors two years ago after working for Fluor Daniel, the engineering arm, of Fluor Corporation. As automation manager, Hanks chief responsiblities are introducing new technologies and improving the utilization of existing automation tools for construction.

more OnPeople see page 21

16

OnTheCover

Skyline
1988
Fluor Constructors develops an in-house rigging group in the Calgary office to support Canadian operations. The group is headed up by John Horon, presently construction engineering manager. CO-OP UPGRADER, Regina, SK Once the reactor arrived on site, this project and Fluor Constructors witnessed another first, the use of an LTL 900 Transi-lift. This was the first time the crane had ever been used on a construction site.

Changing

Since 1949, Fluor Canada has been a leader in heavy lifting. Check out these rigging feats from the past 50 years and the ones to expect in 2001.

1986

CO-OP UPGRADER, Regina, SK A 36 rail axle schnabel car was used to transport this 800-ton reactor from Duluth, MN, to Regina, SK. This was the first time a schnabel car of this size was used in Canada.

1989
PETRO CANADA ISOMERIZATION, Edmonton, AB This project boasts Fluor Constructors first pre-dressed vessel lift in a live refinery. This dehexanizer weighed 185 tons and stood 175 feet. The lift was performed by a Manitowac 4100 Ringer crane.

1052 ft

426 ft 305 ft

1991

1990s

ALBERTA ENVIROFUELS, Edmonton, AB Fluor Constructors lifts this 426-foot flarestack, the tallest of its kind in Western Canada.

1990
ICG UTILITIES, COGENERATION PROJECT, Fort Frances, ON This was one of the first cogeneration plants that Fluor Constructors built. The cogen unit was designed inside a building. An American 9310 Ring Horse crane lifted the HRSG modules into place. Only three rings of this type were ever built for this crane.

1949

CO-OP REFINERY, Regina, SK (photo circa 1950) In 1949, Fluor Corporation came to Canada to work on a $4,000 modification of this refinery. Fluor Constructors would return to perform work at the refinery in the 1980s. 1950s

HUDSONS BAY OIL AND GAS, GAS PROCESSING PLANT, Caroline, AB Gin poles were the standard fare when it came to heavy lifts in the 60s and 70s. This gas processing plant in Caroline, Alberta, used the gin pole technology. (for more information on gin poles
see OnSite, fall 2000)

1960s

1983
UNION CARBIDE PI, Prentiss, AB A Canadian first came for Constructors in the early 80s. An American 11320 Guy Derrick crane was used to lift three converters weighing about 300 tons each.

1978 1967

PACIFIC PETROLEUM, Empress, AB A 300 ton demethanizer column, the largest in North America at the time, is shown enroute from Edmonton, to Empress, AB. This 160-foot-long vessel was part of the worlds largest single-train ethane extraction plant.

1980s

1970s

1991
ALBERTA ENVIROFUELS, Edmonton, AB This DIB column was the tallest lift of this type by Fluor Constructors in Canada. An LTL 1000 Transi-lift positioned the 210-foot-long, 425-ton column into place.

1993
INCO, SO2 ABATEMENT, Sudbury, ON Fluor uses a Liebherr tower crane for the first time in Canada.

1992
HUDSONS BAY MINING, Flin Flon, MB This project used the jack and roll system to move these 120-ton autoclaves into an existing building.

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Battle River Ice Bridge

1993

1993
1990s UNION CARBIDE PII, Prentiss, AB On PII, the rigging group moved a 600-ton vessel, one of the heaviest loads ever to travel along an Albertan highway.

In addition to the logistical feat, the PII project used an RMS jacking system to lift the vessel. This was only the second time the system was used in Canada.

EPSILON POLYPROPYLENE EXPANSION, Marcus Hook, PA, USA Fluor Constructors uses a Demag CC 4800 crane, the first 4800 lift in North America for Fluor. 2000

1995

Fluor Constructors Rigging Engineering group grows into a worldclass team.

SUNCOR MILLENIUM, Fort McMurray, AB For the first time in North America, a 4800 Twin-ring crane was used to lift four coker drums, 415-tons each, on this project. A Demag CC4800 with superlift was used to set the 380-foot tall coker drums.

2000
MUSKEG RIVER OIL SANDS PROJECT, Fort McMurray, AB 2001 Working on a mine site can mean interesting usage of cranes. At MROSP, a crane will be used to lift an excavator out of a hole. The hole will be part of the Athabasca River pumphouse which will take water out of the Athabasca River, transport it along a 9 km pipeline, and back to the mine.

Maria Ang Jennifer Hamilton Jonathan Hayden Arran James Grace Mulchrone Brent Weimer Chris Wickins

COOPERATION It takes the combined expertise of Fluor Constructor rigging specialists in the field and the in-house Rigging Engineering team to successfully and safely execute all lifts.

PETRO CANADA, LEGS, Mississauga, ON Fluor uses a Demag TC 4000 800-ton crane,one of the largest lattice boom truck-mounted cranes in NorthAmerica

1996

BP TOLEDO REPOSITIONING PROJECT, Toledo, OH, USA The Fluor rigging group lifts a coker structure as a complete module for the first time.This was done with a Versalift TC-24000, 1,200 ton crane.

ESSO EDEN, Nanticoke, ON A wheeled-maxer attachment is used for the first time on a Manitowac M250 crane to lift this reactor.

1998

1998

1999

1999

1999

1999
UNION CARBIDE LP7, Prentiss, AB This was the first time a luffing jib was used by Fluor Constructors on a Demag TC-3000 crane with superlift, to set a vessel in a 200-foot structure

KING OF CATS, Saint John, NB The PTC is used again to erect a 433-ton, 138-foot vacuum distillation column. This time the PTC moves from one location to another using tracks.

NOVA E3, Joffre, AB Fluor Constructors performs its tallest lift to date, the C2 Splitter at 227 feet. The Splitter weighs over 1-million pounds (550 tons).

(shown is the EO Absorber)

SHELL MEG, Ft. Sask., AB The Platform Twin-ring Containerized crane (PTC) is used for the first time in North America. The 750-ton reactor is the heaviest lift engineered out of the Calgary office.

The reactor lift

A 1250-ton lift? Thats about the equivalent of lifting the entire population of Fort Saskatchewan, Alberta* with one crane.
*Assuming 14,286 people weighed an average of 175lbs each.

ATHABASCA OIL SANDS DOWNSTREAM PROJECT, Fort Saskatchewan, AB These 1,250-ton reactor lifts will claim the title as the heaviest lifts in Fluor Constructors history. Pictured are VanSeumerens CC4800 crawler cranes with superlift , off-loading three reactor pieces at the site. The same crane will tail the reactors when the PTC executes the lifts in 2001.

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OnPeople

1 Million Hours..and Counting

Muskeg River Reaches a Safety Milestone
By Winston Fynn, MRC Safety Director as printed in Muskeg News

Fluor Corporation Appoints Alan Boeckmann President and Chief Operating Officer
ALISO VIEJO, Calif. January 15, 2001 In a move designed to capitalize on its growing market opportunities, Fluor Corporation (NYSE:FLR) today announced that Alan Boeckmann has been appointed president and chief operating officer, effective February 1, 2001. Boeckmann, who currently serves as president and chief executive officer of Fluor Daniel, one of Fluor s primary business enterprises, will be responsible for all business operations of the corporation, as well as finance, human resources and communications. Philip J. Carroll Jr., Alan Boeckmann, president chairman and chief and chief operating officer executive officer, will retain overall responsibility and accountability for the corporation. Details concerning related management and organizational realignment activities at Fluor will be announced as they occur. Mr. Boeckmann was chosen for this new post because of his in-depth knowledge of the industries in which we operate and his long and distinguished track record of success, said Carroll. This appointment is part of a logical progression in the development of the new Fluor. Boeckmann has more than 28 years experience in the management and technical execution of engineering and construction projects for a variety of industrial and commercial applications, including 25 years at Fluor.

Muskeg River Contractors (MRC) and Albian Sands Energy (ASE) senior construction management sincerely congratulate all project employees for the achievement of 1,000,000 hours without a Lost Time Injury, between March 23 and November 3, 2000 (28 working days). In recognition of this milestone, a celebratory lunch was held in December at the MRC Camp kitchen. In further recognition, jackets and videos were given to all project employees. All site craft, management and supervision, including MRC, ASE and contractors are commended for their dedication and team work in striving for our site mottoes of Zero Accidents and Everyone Home Safely Always.

The team at MRC reaches a safety milestone in 2000

Fluor Constructors Lends Support

In the fall of 2000, the Fort McMurray Chapter of the Canadian Society of Safety Engineering, Canadas premier organization for health and safety professionals, presented the Greg Outhouse Memorial Award of Excellence. Fluor Constructors is proud to be a sponsor of this award. The award is given to an individual who has demonstrated excellent leadership in the health and safety field. This years recipient was Ed Kamps. The award, which was established in 1996, is named after Greg Outhouse, one of the societys founding members in Fort McMurray, and an individual dedicated to the prevention of incidents in the workplace.

OnPersonalBest
Fluor Corporation honours their own
On a recent visit to the new Fluor office in Calgary, Phil Carroll, Fluor Corporation chairman and ceo, recognized local members for their outstanding performance. Recipients included Jennifer Hamilton, Rigging Engineering specialist, Robbie Styba, senior corporate occupational health nurse/WCB coordinator and Amanda Condie, senior communications specialist. Jennifer Hamilton: Through Hamiltons strong leadership of the Rigging group on the Shell MEG project in Fort Saskatchewan, Alberta, Fluor attained two firsts for the Canada office: the heaviest lift, completely designed out of the Calgary office for two 750-ton vessels; and the premiere lift for one of the worlds largest cranes, the Platform Twin-ring Containerised. Presently, Hamilton leads the rigging effort on the Shell Upgrader on even bigger vessels, 1200-tons plus. Robbie Styba: Styba provided leadership in advancing an enhanced workmans compensation and claims management program for all Fluor sites in Alberta. This has significantly added to the bottom line in both direct payments and reduced modifier rates to Fluor Constructors in Canada. Amanda Condie: Condie managed the highly successful Performance Plus program for the NOVA E3 project. It provided significant savings to our customer and a higher incentive payout to Fluor. Due to this program at the E3 site, other customers have shown great interest in these craft productivity initiatives. This gives us a competitive advantage when negotiating pending contracts. We would also like to congratulate Esther Chai, senior administrator and human resources assistant. Chai was recognized by Stephanie Napke, controller for Fluor in Canada, at a weekly department manager meeting. Napke said that Chai is known for her consistent level of dependable service and her positive attitude.

Jennifer

Robbie

Esther

Amanda

Welcome to Constructors
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Milestones...

snapshots of excellence



year
Janice Dyker Kurt Whiffen Rolland Belanger Doug Gillman Jennifer Colley Edie McInnes Joyce Stewart Ronald Groome Roberta Styba Bill Phee Kenneth Ryan Ken Larsen Jerzy Dziubdziela Roger Fisher Gary Mott Alycia Barabash Danette Mandryk Gerald Johnson Patrice Gagnon Dennis Meads Paul Saundry George Holec Gordon Beer Doug Cale Lesley Valentine

Robert Thomson Renee Varney Diane Wiersma

Kevin Metz Edward Corrigal Gary Campbell Steven Johnson Michelle Smith Marcel Brisson Gregory Lawrence Rodney Slaney

Due to space limitations, we regret that we can only print new hires from September to December 2000.

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years



years

Doreen Stephen

Congratulations to all members who recently reached milestones

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Esther Chai

macsback

1991 Alberta Envirofuels

Methyl Tertiary Butyl Ether (MTBE) project, Edmonton, AB Above. A field module makes its way down the main piperack. Note the piperack foundations are complete and civil work continued on both sides of the pipeway. Left. Ian Mac McVittie, Fluor vice president, construction, the originator of the idea.

Ten years ago, people on the MTBE job experienced a Fluor first. Piperack modules were transported, not lifted, into place. It was a first for North America and a first for Fluor Constructors. When the piperack lifting scheme was examined, it was apparent that much of the surrounding foundation work would be delayed to allow for crane access. In came Plan B. Basically, explains Ian Mac McVittie, MTBE construction manager, the idea was to create a field module area where assembly of the modules, which consisted of four precast bents, four pipeway/structural modules, and the

appropriate number of air coolers, could occur. The modules, ranging in weight from 300 to 600 tonnes, would then be transported to their final position using special support frames and Scheulere heavy transport trailers. McVittie says the idea was received with much skepticism. Theyre initial reaction was Are you crazy? But over time and with the clients backing, the idea took root. McVittie says the idea was not entirely new to him. In Norway, modules are used to construct all plants. At one particular refinery, he witnessed piperack modules, without coolers or bents, be-

ing transported from ship to site via selfpropelled modular transporters or SPMTs. Taking that concept, adding coolers, bents and the concept of an assembly area, he applied it to the MTBE site. Once people embraced the idea, there was strong support, particularly from the craft. Once people got on board, it was an idea that gathered its own momentum. That idea also shaved three months off the project schedule. Since then, the procedure has become common practice on Fluor Constructors jobs, when appropriate. Prentiss II, Shell MEG and the NOVA E3 projects all benefited from this innovation.
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