ATOFINA Cosmar Modernization Project, Carville

Total Petrochemicals committed to perform an upgrade at its Carville styrenics complex in Cosmar in spring 2003. The project, called the Cosmar Modernization Project, would increase production while decreasing energy consumption in the manufacturing of styrene.

Harmony's scope of work included the mechanical, electrical and instrumentation construction, as well as overall planning and coordination of subcontractors. Subcontracted work included equipment internals, stress relieving, insulation, modifications to existing equipment, fireproofing, painting, heavy hauling and lifting, and the rebuilding of an existing furnace.

Two process units required major revampments and one unit had to be completely demolished and rebuilt - all in 36 days, requiring a workforce of 1,200 workers.

The project was both aggressive and critical to the plant's operations and production. There were logistical challenges, such as planning the demolition, transportation and re-erection of 4 million lbs. of equipment and pipe material through the plant in 36 days; and managing a workforce of more than 1,200 people to perform a large construction project simultaneously with a major maintenance turnaround.

Innovative programs in the areas of planning, digital photography and manpower management enabled Harmony to accomplish the work safely, on schedule and under budget.