Modular and Moveable Petroleum Loading Docks Phillips 66—Freeport Terminal Projects in Freeport, Texas

The Phillips 66 Marine Terminal, located in Freeport, Texas, on the Gulf of Mexico, is a deep-water berthing facility used for importing and exporting petroleum products. Three docks are being upgraded at the site. The improvements will allow the addition of liquefied petroleum gas (LPG) and pentane plus (C5+) operations. To accommodate long-term port planning, two of the structures will eventually be relocated to increase the size of the Old Brazos River Channel. Originally planned for rehabilitation and expansion, the docks were redesigned midway through the process as new modularly constructed structures. In addition, two of the docks will incorporate the ability to be moved, as a whole, to a future location. The modular construction will allow the current docks to remain in service as the new dock platforms are being constructed. This will minimize the downtime of the facility during the upgrade. The modular pieces will be assembled on-site and placed with the loading arms, gangway tower, crane, control cabin, and additional piping assemblies and utilities already installed on the modular pieces. The facility, located in “Hurricane Alley,” will be subjected to significant wind and wave loads. Deflection control of the docks and product piping support structures is vital to avoid loss of product and to eliminate the use of multiple expansion joints and product piping loops. To obtain the required strength and stiffness, a combination of steel moment frames and braced frames are utilized in the design of the dock platform, pipe way and access way structures. Various aspects of the project are examined, including the steel and concrete modular platform design, modular section to steel pipe pile connection design, access way and product pipe way design, and future removal and reinstallation of two docks. Due to innovative solutions and creative engineering, the project team was able to deliver a product that meets the Client’s future needs within the restricted site layout configuration, with minimal production downtime, and provides an elegant design for the current facility.