Dunbar Methanol Facility Project

In the heart of Dunbar, WV, ParFab transformed a complex methanol construction project into a triumph of efficiency and safety. From initial tube installations to stepping in as general contractor, our dedicated team not only met but exceeded expectations, culminating in over 500,000 manhours with zero OSHA recordables.

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Project Management

Initially awarded the tube installation bid, but after three weeks, asked to take over as general contractor. 

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Long-Term Relationship

 Following project completion, the client engaged ParFab as a maintenance contractor for an additional two years, highlighting the trust and satisfaction with their work during the project.

 
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Quality Assurance

The project boasted a high-quality standard with only 11 total rejects out of thousands of welds, and all major installations, including tanks and vessels, were completed without leaks.

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Peak Workforce

The workforce grew from a small team of 27 to over 230 crew members at peak capacity, including day and night shifts.

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Zero Incidents

Achieved a remarkable safety performance, completing 502,640 man-hours with zero OSHA recordable incidents. This included extensive safety oversight with dedicated personnel for monitoring and reporting.

Project Background

ParFab received a call on 1/21/2021 to bid on tube installation at a new construction site. Understanding the project's significance and aligning it with our expertise in the methanol industry, we promptly prepared a bid. Just five days later, on 1/26/2021, we were awarded the contract.

As our team began work on the initial scope, the client's needs expanded, leading us to submit bids for additional tasks. Three weeks into the project, the client requested that ParFab take over as the general contractor. This marked a pivotal moment, necessitating a focused effort to realign the project with its original timelines. We worked as a group to pull the project back in line and back on schedule within five weeks. ParFab completed the project on 2/4/2022.

When the project was completed the client asked ParFab to stay on as their maintenance contractor until the unit was lined out and running properly which we did for an additional 2 years.

Industry

Methanol

Project Scope

New Construction

Project Challenge

Three weeks into the project, it became clear that additional support was needed. ParFab was asked to step in as the general contractor, taking on the responsibility of getting the project back on track and ensuring it met its deadlines.

How We Helped

Through collaboration and focused efforts, our team successfully realigned the project within five weeks, completing it on 2/4/2022. Following project completion, the client requested that ParFab continue as their maintenance contractor to ensure the unit operated smoothly, a partnership we honored for an additional two years.

Manpower

The workforce and PFS personnel needed to complete the project.

Crew Expansion Timeline

Initially, the Parfab team had 8 welders, 10 pipe fitters, 5 boilmakers and 4 refractories. Within four weeks, we had grown to 200 plus crew members. At it's peak, we had a total of 230 plus crew members on-site between the day and night shifts. 

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Total # of welders

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Total # of pipefitters

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Total # of boilermakers

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Total # of crew members

Health, Safety, & Environmental

This project under ParFab supervision completed 502,640 manhours with zero OSHA recordable. Parfab had 1 safety manager, 1 safety supervisor, and 4 safety techs on days. Nights considered of small crews and ParFab had 1 safety supervisor. 
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Project Quality & KPI Overview

This project had 1 quality manger, 4 CWI's, and 4 quality techs. Key performance indicators (KPIs) included the installation of 200+ pieces of equipment, 21,750 flange makeups, and 285 hydro tests, all completed at 100% with zero startup leaks. The team installed 11,362 linear feet of small carbon steel piping, 8,115 linear feet of large carbon steel piping, and 80 heater tubes. A total of 4,545 welds were made with 11 rejects, reflecting the project’s exceptional quality and efficiency.

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