Refinery Construction Plant and Equipment: 50 Example Fleets by Work Type
This page provides 50 example plant and equipment mixes for different stages of
refinery and large process plant projects – site prep, foundations, structural steel, vessels,
piping, tanks, flare systems, utilities, shutdowns and rehabilitation.
Each card represents a practical plant + equipment fleet that works together as a system.
Use these as starting points when developing methodology‑led estimates, programmes and
Efficient Construction Cost (ECC) models. Always adjust for your specific
process units, layout, live‑plant interfaces, materials and safety rules (including hazardous areas).
Site Preparation & Civil Earthworks
1. Greenfield Refinery Site Bulk Earthworks
Use case: Cut/fill to create plant, tank farm and utility areas.
Plant & Equipment Mix
- 3–4 × 30–50 t excavators
- 8–12 × 25–30 t articulated dump trucks
- 2 × Dozers (D8–D10) for bulk push/levelling
- 2 × Graders with GPS control
- 3 × Smooth drum / padfoot rollers
- 2 × Watercarts
2. Brownfield Expansion Earthworks
Use case: Extend or upgrade units inside operating refinery.
Plant & Equipment Mix
- Compact 8–20 t excavators for constrained areas
- Skid steers for tight workfaces
- Small dumpers or tip trucks
- Compact rollers and plate compactors
- Dedicated spotters and fire watch equipment
3. Process Unit Pad Formation
Use case: Fineshed formation for piperacks, equipment and structures.
Plant & Equipment Mix
- 20–30 t excavators
- Grader with 3D/GPS
- Padfoot & smooth drum rollers
- Skid steer for final trims
4. Roads & Access within Refinery Plot
Use case: Internal roads, laydowns and fire tender access routes.
Plant & Equipment Mix
- Graders & rollers
- Asphalt or granular surfacing plant
- Watercart & dust suppression
Foundations, Piles & Structural Concrete
5. Piled Foundations for Process Structures
Use case: Piled caps for pipe racks, columns and heavy equipment.
Plant & Equipment Mix
- CFA or driven pile rig (diameter to design)
- 80–150 t crane for cages/casings
- Concrete pump & agitators
- Excavator for pile caps and trimming
6. Strip & Pad Footings in Process Units
Use case: Foundations for equipment skids and pipe supports.
Plant & Equipment Mix
- Mini/midi excavators (5–14 t)
- Plate compactors
- Concrete line pump
- Light crane/telehandler for formwork & reo
7. Equipment Foundation Blocks
Use case: Large inertia blocks for compressors, pumps and rotating equipment.
Plant & Equipment Mix
- 20–30 t excavator
- Formwork systems & anchor bolt templates
- Concrete pump & vibrators
- Survey instruments for level/tolerance
8. Piperack Foundations
Use case: Strip/pile caps and columns for multi‑level piperacks.
Plant & Equipment Mix
- Piling rig (if deep foundations)
- Mini/midi excavators for pile caps and strip footings
- Concrete pump
- Small crane for rebar cages
Structural Steel, Piperacks & Access Structures
9. Piperack Steel Erection
Use case: Multi‑bay piperacks through process units.
Plant & Equipment Mix
- 80–200 t mobile cranes (depending on reach and bay size)
- Telehandlers for secondary steel
- MEWPs (boom lifts) for bolting, bracing and access platforms
- Torque tools and survey gear for plumb/line
10. Process Structure Steel Frames
Use case: Steel structures around columns, reactors, vessels.
Plant & Equipment Mix
- 200–400 t crane (for tall/heavy frames)
- Smaller assist cranes/telehandlers
- MEWPs for connection and deck installation
11. Access Platforms, Stairs & Ladders
Use case: Steel stairs, landings and access platforms throughout units.
Plant & Equipment Mix
- Telehandler for prefabricated platform modules
- Scissor lifts/MEWPs for fix‑off and guardrails
- Light crane truck in tight units
12. Pipe Support Steel along Piperacks
Use case: Secondary steel supports, guides and shoes.
Plant & Equipment Mix
- Telehandlers
- MEWPs
- Hand tools, welders and torque equipment
Vessels, Columns & Heavy Lifts
13. Vertical Column Installation
Use case: Distillation columns and reactors erected in process units.
Plant & Equipment Mix
- 400–800 t crawler or mobile crane (depending on height/weight)
- Tail crane (200–400 t) for upending
- Skates and jacks for positioning at grade
- MEWPs for nozzle and platform hook‑up
14. Horizontal Vessel Installation
Use case: Drums, exchangers and horizontal pressure vessels.
Plant & Equipment Mix
- 150–300 t mobile crane
- Skates, rollers and jacks for final alignment
- MEWPs for support and piping connections
15. Modular Skid Lifts
Use case: Prefabricated skid modules (pumps, exchangers, filters).
Plant & Equipment Mix
- 80–200 t mobile cranes
- Forklifts/telehandlers for smaller skids
- MEWPs for interconnection piping and cabling
16. Heavy Lift Planning Test Setup
Use case: Trial rigging and clearances for critical lifts.
Plant & Equipment Mix
- Cranes used for final lifts (at test loads/angles)
- Test weights and load cells
- Survey monitoring and clash detection tools
Piping – Process, Utility & Offsite
17. Pipe Spool Delivery & Setting on Racks
Use case: Install shop‑fabricated spools onto piperacks and structures.
Plant & Equipment Mix
- Cranes (80–150 t) for main lines
- Telehandlers for smaller spools
- MEWPs for bolt‑up and welding at height
18. Underground Process/Utility Pipework
Use case: Buried lines between units and tank farms.
Plant & Equipment Mix
- Mini/midi excavators with trench shields
- Pipe fusion/welding rigs
- Plate compactors and small rollers
- Vac trucks for service proving
19. Above‑Ground Utility Pipe Racks
Use case: Steam, condensate, nitrogen, instrument air, cooling water.
Plant & Equipment Mix
- Telehandlers and forklifts
- MEWPs for support install and pipe placement
- Welding sets, preheat gear and NDT equipment
20. Flare & Relief Header Piping
Use case: Large bore flare headers around site.
Plant & Equipment Mix
- Cranes for header sections
- MEWPs/rope access (if elevated)
- Welding & PWHT (post‑weld heat treatment) equipment
Tank Farms, Bunds & Associated Works
21. Tank Pad Formation
Use case: Form and compact tank foundations and ring walls.
Plant & Equipment Mix
- 20–30 t excavator
- Grader and rollers
- Plate compactors near ring walls
- Survey gear for level and slope control
22. Above‑Ground Storage Tank Shell Lifting
Use case: Erect large diameter crude/product tanks.
Plant & Equipment Mix
- Hydraulic jacking system or large crawler cranes
- Shell plate handling gear (vacuum lifters or clamps)
- Scaffolding/MEWPs inside/outside shell
23. Bund (Dike) Construction
Use case: Earthen or concrete containment around tanks.
Plant & Equipment Mix
- Excavators and dozers
- Rollers and watercarts
- Liner installation gear (if lined)
- Rockwork/riprap placement plant for slopes
24. Tank Farm Piping & Manifolds
Use case: Suction/discharge lines, manifolds and pump piping.
Plant & Equipment Mix
- Mini/midi excavators for trenching
- Pipe welding/fusion equipment
- Crane truck for valves and manifolds
- Compaction plant and testing gear
Flare Systems, Stacks & High Structures
25. Flare Stack Foundation & Piles
Use case: Deep foundations for tall flare stack.
Plant & Equipment Mix
- Piling rig (bored or driven, as designed)
- Crane for cages and anchors
- Concrete pump and mixers
- Survey for anchor bolt templates
26. Flare Stack Erection
Use case: Install single tall flare or multiple‑head towers.
Plant & Equipment Mix
- Heavy lift crane (400–800 t) or gin pole system
- Tail crane or temporary guy systems
- MEWPs or rope access for head installation
27. Flare Header & Knockout Drum
Use case: Civil and mechanical works at flare KO drum.
Plant & Equipment Mix
- Civil plant (excavators, formwork, concrete pump)
- Cranes for drum and header pieces
- Piping installation fleet
Electrical, Instrumentation & Control Rooms
28. Substations & MCC Building Fit‑Out
Use case: MV/LV switchgear, MCCs and drives installation.
Plant & Equipment Mix
- Forklifts / pallet jacks for switchgear
- Small cranes/gantries inside buildings
- Scissor lifts for cable trays & bus duct
29. Cable Ladder & Tray Installation across Plant
Use case: Extensive tray runs along piperacks and structures.
Plant & Equipment Mix
- MEWPs along piperacks
- Telehandlers for tray and support steel
- Hand tools for fixing brackets and supports
30. MV/LV Cable Pulling
Use case: Power, control and instrumentation cables to units.
Plant & Equipment Mix
- Cable drum stands
- Cable winches and rollers
- Test equipment (megger, OTDR for fibre)
31. Instrumentation & Control Panel Install
Use case: Field instruments, marshalling cabinets, analyzers.
Plant & Equipment Mix
- Scissor lifts/MEWPs for instruments at height
- Portable test/calibration sets
- Small cranes for analyzer shelters and cabinets
Shutdowns, Turnarounds & Live‑Plant Works
32. Turnaround Scaffolding & Access
Use case: Large shutdown with extensive scaffolding in process units.
Plant & Equipment Mix
- Scaffold material and erection crews
- Telehandlers/forklifts for tube & fittings
- MEWPs to supplement scaffold access
33. Heat Exchanger Pull & Refurbishment
Use case: Remove, refurbish and reinstall exchangers during shutdown.
Plant & Equipment Mix
- 80–200 t mobile crane or gantry/monorail systems
- Skates and rollers
- Tube cleaning and inspection rigs
34. Column/Tower Internal Works
Use case: Tray/baffle replacement and internal inspections.
Plant & Equipment Mix
- Confined space access gear
- Portable internal access platforms
- Specialist lifting devices inside shells
35. Hot Tap & Tie‑In Works
Use case: New connections onto live lines (where permitted).
Plant & Equipment Mix
- Hot tap machines and isolation tools
- MEWPs or scaffold for access at height
- Welding and NDT plant
36. Coating & Insulation Renewal
Use case: Replace CUI‑affected insulation and coatings.
Plant & Equipment Mix
- Scaffolds/MEWPs
- Insulation removal tools and cutting gear
- Blasting/UHP water jetting and coating pumps
Demolition, Decommissioning & Rehabilitation
37. Decommissioning Old Process Units
Use case: Demolish redundant units in phased programme.
Plant & Equipment Mix
- 30–50 t excavators with shears and pulverisers
- High‑reach excavator (if necessary)
- Skid steers and loaders for debris
- Trucks for scrap/waste removal
38. Tank Demolition & Removal
Use case: Cut and remove above‑ground storage tanks.
Plant & Equipment Mix
- Excavators with shears, or manual cutting and controlled collapse
- Cranes for lifting shell segments (if staged removal)
- Skid steers/trucks for scrap handling
39. Underground Services Removal & Blinding
Use case: Remove or inert old pipelines and ducts.
Plant & Equipment Mix
- Mini/midi excavators
- Vac trucks and flushing systems
- Foam/ grout fill injection pumps
40. Site Remediation & Capping
Use case: Soil remediation and long‑term capping after decommissioning.
Plant & Equipment Mix
- 20–30 t excavators
- Haul trucks for contaminated soil
- Stabiliser or mixing plant (in‑situ treatment if used)
- Graders and rollers for capping layers
Specialty Systems & Safety‑Critical Work
41. Firewater & Foam Systems
Use case: Fire rings, monitors and deluge systems across refinery.
Plant & Equipment Mix
- Trenchers or excavators
- Pipe fusion/welding rigs
- MEWPs for elevated deluge and monitors
- Hydrotest gear
42. Blast/Fire‑Rated Offices & Control Rooms
Use case: Modular blast‑rated buildings within process area.
Plant & Equipment Mix
- 200–400 t crane (if large modules)
- Crane trucks for smaller modules
- Skates/jacks for alignment
43. Access & Egress Upgrades
Use case: Extra stair towers, escape ladders, emergency platforms.
Plant & Equipment Mix
- Telehandlers for stair modules
- MEWPs for connections
- Hand tools and torque equipment
44. Gas Detection & Safety Instrumentation Retrofits
Use case: New gas detectors, ESD pushbuttons, beacons.
Plant & Equipment Mix
- Scissor lifts/MEWPs
- Portable test/calibration kits
- Cable pulling and termination tools
Survey, Monitoring & ECC/TOC Pilot Works
45. 3D Laser Scan & As‑Built Survey
Use case: Capture complex brownfield geometry before expansion.
Plant & Equipment Mix
- Laser scanners and total stations
- Access platforms/MEWPs
- ATEX/EX‑rated equipment in classified zones
46. Structural Monitoring of Critical Units
Use case: Monitor differential settlement or deflection during works.
Plant & Equipment Mix
- Survey prisms and robotic total stations
- Vibration/strain gauges and data loggers
- Access ladders and small scaffolds
47. Vibration & Noise Monitoring During Piling/Demolition
Use case: Protect operating plant and neighbours.
Plant & Equipment Mix
- Portable vibration monitors
- Noise meters & loggers
- Temporary barriers or screening plant
48. ECC/TOC Pilot for Modular vs Stick‑Built Approach
Use case: Trial modular skids vs stick‑built for a small unit.
Plant & Equipment Mix
- Modular lift cranes
- Stick‑built assembly tools
- Instrumentation to capture installation time, rework and safety performance
49. Pilot Section for New Coating/Insulation System
Use case: Test new CUI mitigation system on limited area.
Plant & Equipment Mix
- Blasting/UHP jetting kit
- Coating pumps & insulation tools
- Scaffolds/MEWPs
50. Integrated ECC/TOC Methodology Review Zone
Use case: Trial combined civil/structural/mechanical methodology in a test area.
Plant & Equipment Mix
- A representative mini‑fleet from civil, structural, piping & E&I
- Full safety and permitting regime as per live works
- Monitoring tools for productivity, rework, access conflicts
Need Help Selecting or Optimising Refinery Plant and Equipment Mixes?
These example fleets are starting points only. On a live refinery or process plant project, the optimal
plant and equipment mix depends on:
- Unit layout, elevation and modularisation strategy
- Interface with live operations, shutdown windows and hazardous area rules
- Ground conditions, tank farm layout and offsite/utility constraints
- Required production, safety constraints and ECC/TOC objectives
We can help you:
- Develop methodology‑led plant and equipment mixes for each refinery work package
- Align staging, modularisation and shutdown planning with realistic productivity and Efficient Construction Cost (ECC)
- Compare construction strategies (stick‑built vs modular, day vs night, unit‑by‑unit shutdowns) on a time–cost–risk basis
- Feed real project learning back into future refinery bids and planning
Use the form below to discuss your project.
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