Rally’s Client required an increase to the ethanol blending capacity at their truck loading terminal. The scope was to replace the four existing ethanol blending pumps with larger pumps that could meet the increased flow requirements. First, Rally conducted a pre-FEED study to confirm if the existing infrastructure could accommodate the larger pumps, which would determine the scope of this project and provide a +50/-30 capital cost estimate. Following the study, Rally proceeded with front-end engineering design (FEED) and then detailed engineering.
The overall system hydraulics and pump controls were modeled and re-engineered to increase blending accuracy. By upgrading the control systems, ethanol header pressure was reduced, improving energy efficiency. Pressure safety valves (PSVs) were retrofit to the existing ethanol headers to improve safety. Strategic upgrades were also made to structural foundations, power systems, and interconnecting piping. Periodic 3D model reviews kept all stakeholders engaged and brought continuous improvement to the design.
Rally provided all phases of engineering support to this project, from initial concept development to detailed engineering. Rally produced the material requisitions (MRs) and construction work packages (CWPs) required to procure new materials and integrate them into the brownfield facility.
The new ethanol pumps and filter vessels were packaged into modules, which minimized on-site work in live operating areas. A new prefabricated electrical building likewise simplified the on-site construction work. Piping tie-ins were designed in a way to minimize their impact on normal truck loading operations.
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