Buried pipelines for 24 different commodities were in service for 50 years or more. Many of these lines conveyed the refinery’s main products to their sales tanks. Inspections and maintenance of these piping systems were costly, and the risk of a high-consequence failure of one or more lines due to corrosion increased with each passing year. A project was created to reconstruct the buried piping above grade on a new pipe rack.
Rally worked with the Client to develop a design basis which clarified the scope of the project. The team then progressed into detailed engineering and eventually construction support. Key project scope items included pipe rack design, piping layout and tie-in strategy, earthworks and grading improvements, a new bridge crossing, modifications to existing steel structures, and relocation of existing facilities.
The primary pipe rack was designed as a single two-level module that was fabricated offsite. Modularization of the pipe rack reduced overall project cost and shifted work hours from the field to a lower-risk shop environment.
Rally collaborated with the Client’s stakeholders to optimize the tie-in plan and produced construction work packages (CWPs) targeted to each tie-in opportunity. Tie-ins between new and existing piping were staggered over a three-year period, taking advantage of schedule system outages.
Significant improvements were also made to the groundwater drainage and local power distribution lines in the project area.
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