Tesoro’s Avon Wharf Facility Pile Cap Frames

Four (4) pile cap frames and interconnecting pipe sections for replacement of the Avon Wharf facility at Tesoro’s Martinez, CA refinery. The largest frame section weighed over 164 Tons (328,000 lbs).

4
PILE CAP FRAMES
3.5"
THICK JOINTS
0
ACCIDENT/INCIDENTS

The Process

Four (4) pile cap frames and interconnecting pipe sections for replacement of the Avon Wharf facility at Tesoro’s Martinez, CA refinery. The largest frame section weighed over 164 Tons (328,000 lbs).

Fabrication of the large subassemblies began at T BAILEY’s Anacortes fabrication facility. We were given a design package from the owner/engineer from which we produced our fabrication drawings.  Avon Wharf was a unique project given the complex geometry.  It required unique supporting structures during the fabrication process.  Since the pile cap frames and interconnecting pipe sections were going to fit onto an already existing structures at the customer’s facility, accuracy was essential. With the assistance of T BAILEY’s manufacturing engineer, we created a custom automated burning machine for each of the intricate pipe joints which helped in manufacturing of the pipe and preparation of the bevels. This allowed some of the sections that were 1.25 to 3.5” thick to be prepared and joined with incredible accuracy adding to the efficiency of the job.

The tubular sections of the project were built using API 2B (non-monogramed) standards.  API 2B Specification for the Fabrication of Structural Steel Pipe is similar to ASTM A252 but API 2B has more quality control performed on the welded seams, including 100% Visual inspection, 100% RT or UT of the circumferential seams, and 10% RT or UT of the longitudinal seams. Our in-house SNT-TC-1A Level III inspector performed 100% UT inspection ensuring full penetration of all welds. Several of the heavier walled subassemblies required off-site post weld head treatment.

The initial coatings system was applied at our fabrication facility and consisted of an inorganic zinc primer, a second coat of epoxy and a polyurethane top coat with a holdback at each of the spliced joints where field welding was necessary. The coatings system was applied in accordance with SSPC-PA.  Our in-house NACE Level 3 Certified inspector certified that the coatings system was applied to specification.

After initial fabrication of the subassemblies, they were transported to an off-site lot in Anacortes that allowed for further assembly and allowed access to a barge for shipment. T BAILEY, INC. then utilized our union field Boilermakers to fit and weld the large subassemblies into four (4) large pile cap frames.

Final coating was applied at the spliced joints where field welding was performed.  Due to the proximity next to the water, a full containment was necessary in order to mitigate environmental concerns.

For the final phase of this project, T BAILEY utilized a subcontractor with two 500 Ton rolling platforms to move the subassemblies to the water’s edge for a barge based derrick crane to lift the sections for delivery to Tesoro’s Martinez site.

Results of T BAILEY's automated burning machine
Results of T BAILEY's automated burning machine
BRIEF
BRIEF
Moving pile caps down to the crane barge
Moving pile caps down to the crane barge

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We’re designed to perform custom fabrication of heavy structural and plate products, and can directly ship oversized loads via barge, rail, or truck to your location.

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