ASI WA Steel Awards 2008 Steel Fabricators Award

Transcription

1 BP Naphtha Splitter Column ASI WA Steel Awards 2008 Steel Fabricators Award

2 Introduction from Liam Donley Good evening fellow engineers. My name is Liam Donley and I am the Senior Project Manager at the United Group Resources Kwinana Fabrication facility. In August this year, BP commissioned a new Naptha Splitter at the BP Kwinana Refinery. The commissioning of the Naptha Splitter was the culmination of some 18 months work for United Group Resources. By way of history, in March 2007, United Group Resources tendered for BP Kwinana s Naphtha Splitter Column project. BP conducted the tender process utilising global procurement channels, and in May 2007 United Group Resources were awarded the contract on the basis of local presence, capability and dependability on quality and schedule deliverables. United Group Resources provided engineering design, detailing, supply, fabrication and delivery to site of a new Naphtha Splitter Column. The BP Naphtha Splitter column is the largest single fabricated vessel United Group Resources has ever fabricated. The project was completed on schedule, with zero health and safety recordable injuries and zero quality issues. United Group Resources provided in-house engineering design and detailing of the Naphtha Splitter Column. The design model was developed using the Tekla Structure (XSteel) shop detailing software package enabling seamless interface and transition between the engineering design and detailing phases. The smooth progress of the entire design and fabrication project was possible due to the integrated engineering, fabrication and construction delivery model provided by United Group Resources. Design of the Naphtha Splitter Column also involved close liaison with the balance-of-plant design engineers (Worley Parsons) in numerous 3Di design review sessions. This collaboration allowed refinement of the interface with the associated civil, piping, electrical and instrumentation works. The 64m high x 4.5m diameter pressure vessel weighs 308 tonnes and involves a very complex interaction of internal process trays, baffles, numerous piping nozzles, and external access platforms, ladders & walkways. Due to the immense size and weight of the splitter column, United Group Resources constructed the shell of the vessel in 3m x 4.5m diameter sections in its Kwinana workshop. This modular construction method was used to maximise resources and optimise schedule compliance. 2

3 Engineering Design & Modelling 65m high x 4.5m dia Class 2A pressure vessel weighing 308t and involving a complex interaction of internal process trays, baffles, numerous piping nozzles, and external access platforms, ladders & walkways. Design carried out to AS1210, AS4100 & AS1657 incorporating all current amendments and BP s own stringent specifications and standard details. In-House FEA analysis of critical areas. Engineering model developed directly in Tekla Structures (XSteel) in-house at UGL Resources offices in the Perth CBD. 3

4 Engineering Design & Modelling Increased value proposition to this important Client via complete end-to-end service, from engineering design through to delivery. Streamlined and integrated workflow which provided cost and schedule efficiencies. Close liaison between the Client s team, the balance-of-plant design engineers (Worley Parsons) and the fabrication team, in numerous 3Di Design Model Review sessions. Refined interface with the associated civil, piping, electrical and instrumentation works. Fabrication deliverables produced directly from the approved 3Di Model. 4

5

6

7 Workshop Preparation December/January Clearing and preparing the 3600 sq.m workshop Laying trolley tracks. Laser aligned, embedded and cemented into flooring 5

8 Work in Progress - January Flat bar sectional rolling Reinforcement & insulation retaining rings Rolling angle iron Rolling saddle rings Shell rolling Sub-arc welding of shell plate 6

9 Work in Progress - February Formed end cap External saddle rings Head nozzles in place Flux cored vertical up weld Loading shells 7

10 Work in Progress - March End cap to shell Formed and welded tail lug Inner saddle ring Joining the shells Internal tray supports 8

11 Fabrication Support Issues Workshop Handling on custom built roller trolley Special support system for 1,000+ tonne hydro test loads Custom stiffening collar for jacking and transport conditions Extensive lifting study and stiffening arrangements. Custom built platforms for safe access. 9

12 Work in Progress-April Joining shells installing nozzles Internal fit out with trays and baffles Dimensional accuracy achieved with 17,000 bolts fitted without requiring any rework 10

13 Work in Progress-May Internal fit out of ASTM A S stainless steel trays & baffles 11

14 Work in Progress-May 12

15 Work In Progress-June 13

16 Hydro test preparation Installation of the support beams grouted to the floor and welded to the stiffening rings side & underneath to distribute and support the total projected weight of 1380 tonnes after filling the column with water to conduct the Hydro test. 14

17 Hydro test Filling the column with water to Hydro Test to a pressure of 750 kpa which was maintained for a duration of 1.5 hours without a weld failure 15

18 Blast, Paint & Installation of Jacking Frames Cordon off and encapsulate work area for blast & paint Blast clean to AS1627,Part 4 Class 3 blast profile 35 to 65 microns 3 coat paint with: Interzinc 86 to 75 microns Intertherm 50 to 25 microns Intertherm 50 to 25 microns 16

19 Insulation & Cladding Apply fire retardant to 4m skirt (applied on site) Apply internal & external application of Chartek-7 to 4m from base Skirt: 4mm Chartek-7 and CS GD 250 Cladding 17

20 Cladding Complete Insulation and Cladding 100mm Rockwool Insulation 1.2mm Corrugated SS and Corrugated Zincalume 18

21 Preparing For Transportation Jacking the column up to allow transportation Jacked up to a clearance of 2.1m 19

22 Delivery 20

23