Energy Transfer Marcus Hook Industrial Complex

Dock 1A, 2A, and Fire Water Pump EPC Contracts
Sunoco-Marcus-Hook-dock-2a

Project Overview

S. T. Hudson Engineers, Inc. was selected by Sunoco Logistics Partners, L.P. to design & construct a new dock for the loading of ethane, propane, and butane at the Marcus Hook Industrial Complex in Marcus Hook, PA.

Sunoco-Marcus-Hook-dock-1a

Project Stats

Work for all three projects took place over the course of three years. Below you will find the improvements that S. T. Hudson made for each project.

Dock 2A Modifications (Sept 2013 – Dec 2016)

Total Project Budget = $21,000,000

New Structures:

  • Breasting dolphins with rock anchor foundations
  • Fender systems
  • Mooring quick release hooks
  • Gangway system
  • Jib crane
  • Dock house operations center
Dock 1A Rehabilitations (Jan 2016 – Dec 2016)

Total Project Budget = $75,000,000

New Structures:

  • Dock platform, roadway, and pipeway
  • Breasting dolphins
  • Mooring dolphins
  • Fender systems
  • Mooring quick release hooks
  • Fully automated gangway system
Firewater Intake System (Nov 2015 – Nov 2016)

Total Project Budget = $27,300,000

New Additions:

  • Permanent cofferdam water intake bays
  • Concrete intake structures
  • Automated firefighting pumping system
  • Underground water piping system
  • Electrical, mechanical, and instrumentation integration and commissioning

Project Data Points

950
Linear ft of
Pipe Rack Modules

Most of the models were more than 80ft in length and over 15ft tall.

6
New Mooring
Dolphins Added

as well as 2 new breasting dolphins and 2 new breasting coffercells.

8
New Walkways
Constructed & Installed

Connecting all 10 new dolphins to incorporate the complete dock upgrade.

1
New Gangway
And Crane Tower

Estimating, purchasing, and construction services.

Our Team

Want to learn more about our individual expertise? Get to know our team!

Robert Hudson, P.E.

President and Chief Executive Officer
Robert Hudson, P.E. Robert Hudson, P.E.

Robert Hudson, P.E.

President and Chief Executive Officer

Mr. Hudson is a Senior Civil/Structural Engineer with over 40 years of experience in the design and construction of marine facilities. He has special expertise in construction methods and estimating. Over the course of his career, Mr. Hudson has been involved in a wide range of construction activities, with emphasis on marine structures, bridges and pile foundations.

In 2002, Mr. Hudson became President and Chief Operating officer of S. T. Hudson Engineers, Inc and continues to serve in that capacity today. Mr. Hudson is a Registered Professional Engineer in New Jersey, Pennsylvania and Delaware. His professional affiliations include The Ports of Philadelphia Maritime Society; The Deep Foundation Institute; The American Society of Civil Engineers and The National Society of Professional Engineers.

James Thomas

Chief Operating Officer & Vice President
James Thomas James Thomas

James Thomas

Chief Operating Officer & Vice President

Mr. Thomas is Hudson’s Chief Operating Officer and has over 35 years of broad experience in the planning, design, management and execution of marine construction and dredging projects.

Mr. Thomas has worked on projects throughout the United States, the Caribbean, South America and the Middle East. His marine construction and dredging experience includes participation in small to large scale capital works, maintenance and superfund projects. He has managed the construction of offshore ocean ship berthing facilities as well as the construction of harbor berth facilities and terminals.

Leslie (Hudson) Gerhard

Vice President
Leslie (Hudson) Gerhard Leslie (Hudson) Gerhard

Leslie (Hudson) Gerhard

Vice President

Ms. Gerhard is Vice President at S. T. Hudson Engineers, Inc. with over 15 years of experience in marketing, company operations, contract administration, and client relationships. She is responsible for day-to-day office operations, generating and overseeing proposal submissions, marketing efforts, contract administration, team recruitment, and coordination and administration of the summer internship program. In addition, she is involved in developing business among existing clients and new clients which contribute significantly to corporate revenues.

Ms. Gerhard is part of the fourth generation of Hudson family members working in the business, working side by side with her father, Robert S. Hudson, P.E., to lead S. T. Hudson Engineers, Inc.

Anthony DePasquale, P.E.

Vice President & Director of Marine Engineering and Environmental Services
Anthony DePasquale, P.E. Anthony DePasquale, P.E.

Anthony DePasquale, P.E.

Vice President & Director of Marine Engineering and Environmental Services

Mr. DePasquale is a Civil & Geo-technical Engineer with 37 years of experience as a designer, construction manager, negotiator, and permitting consultant with the US Army Corps of Engineers. He specializes in the design, management, and construction of flood protection systems, bulkhead rehabilitation, and waste and dredge disposal containment facilities.

In addition, he has reviewed and negotiated numerous construction contract claims, permitting issues, and engineering disputes. Mr. DePasquale's experience has given S.T. Hudson valuable insight into the permitting process and environmental impact assessments from the viewpoint of the USACE and other regulatory agencies.

William Jenkins

Vice President & Director of Marine Services
William Jenkins William Jenkins

William Jenkins

Vice President & Director of Marine Services

Mr. Jenkins has 17 years of experience and a comprehensive knowledge of various hydrographic technologies and methods.

Recently, Mr. Jenkins has applied his talents to implementing various multibeam hydrographic surveys for ship navigation safety, object detection, clearance surveys, sediment transfer surveys, pre- and post-dredge surveys, and bridge inspection scour monitoring.

John Carroll

Director of Mechanical Services
John Carroll John Carroll

John Carroll

Director of Mechanical Services

Mr. Carroll is a Mechanical Engineer with over 30 years of experience as an engineer and project manager for the petrochemical industry.

Mr. Carroll’s specialty focus is on terminal engineering and consulting, and he has worked for, on, and with many of the major terminal facilities on the U.S. East Coast.

This experience has given S.T. Hudson the capacity to execute terminal design projects to complement our marine engineering services and make Hudson a turn-key design company capable of providing engineering services for the whole terminal.

Michael Barbetta, P.E.

Department Manager - Marine Structures Engineering
Michael Barbetta, P.E. Michael Barbetta, P.E.

Michael Barbetta, P.E.

Department Manager - Marine Structures Engineering

Mr. Barbetta is a Senior Engineering Manager with over 30 years of experience in marine terminal, building and petrochem projects.

Mr. Barbetta is experienced in managing civil/structural engineering projects and personnel, as well as executing front end loading through detailed design. He is familiar with structural engineering software such as OPTIMOOR, STAAD, Visual Analysis, MathCAD, AutoCAD and L-Pile. Additionally, Mr. Barbetta performs engineering work-flow processes, QA/QC and constructability reviews, prepares feasibility studies, develops engineering budgets and schedules, and supports business development.

Alan Stoner

Chief Draftsman / Senior Designer
Alan Stoner Alan Stoner

Alan Stoner

Chief Draftsman / Senior Designer

Mr. Stoner has 46 years of experience in all aspects of drafting (including years in CADD) and field survey work. He has been with Hudson Engineers for 45 years. As Chief Draftsman/Senior Designer for S. T. Hudson Engineers, his primary responsibility involves training, supervision, and scheduling of personnel and supervising the accuracy, completeness, and timeliness of the work in the drafting department.

Mr. Stoner serves as the liaison between the drafting, engineering, and field survey departments. He is responsible for the layout and coordination of drawings in the civil, structural, mechanical and electrical disciplines. He is also responsible for the maintenance of all drawing files and project records.

Project Results

The project involved three separate projects: the rehabilitation of Dock 1A, a rehabilitation and upgrade of Dock 2A, and the retrofit installation of a fire water intake system on Dock 1A.

Due to the extensive work to be completed as well as the complexity of the project, S. T. Hudson was able to provide a range of services. Hudson’s scope of engineering services included a detailed OPTIMOOR analysis, conceptual design, cost estimates, engineering calculations, construction documents and federal and state permits and construction management services. This project demonstrated Hudson’s capacity to carry a project through every phase of the project cycle.

In all three projects, the major challenge was to take an aging existing infrastructure and retrofit it to accommodate the newest class of LPG tanker vessels.  This required major modifications to the existing structures, which had to be achieved without damaging their structural integrity. We also overcame logistical challenges in transporting and installing the large prefabricated pipe modules that are necessary to safely transfer the product from refinery to the vessels.

Refinery-dock-2a-modifications-in-progress

Project Goals

Before S. T. Hudson completed this work, this facility was a dormant refinery. The upgrades that we recommended, designed, and helped to construct turned this facility into a major export terminal that takes petroleum products, piped in from western PA, and sends it to markets in Europe, while creating thousands of new jobs for the local community.

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