The plant’s vacuum tower was nearing the end of its service life and needed replacement. The original vacuum tower PSV was vented to atmosphere; the revamped design redirected the PSV outlet to an existing flare header approximately 200 feet away, preventing atmospheric releases. The vacuum tower was simultaneously redesigned to handle higher back-pressure, with improved maintenance access and safety. Laser scan technology was leveraged to achieve minimal rework during construction.
The project scope was divided into pre-shutdown, shutdown, and post-shutdown work phases. Rally engineered new lifting and tailing lugs to safely remove the original vacuum tower. New piping, instrumentation, and electrical scope facilitated the installation of new vacuum condensers and ejectors in the unit.
The new tower was pre-dressed with platforms to accelerate the turnaround work. The new platforms were designed for seamless integration with an existing stairway.
The design scope included all piping, structural steel, electrical, instrumentation and tie-ins to the existing plant. Electrical heat tracing was installed post-shutdown.
Rally provided procurement support for the new vacuum tower. Rally also produced Construction Work Packages (CWPs) to execute the brownfield vacuum unit modifications. With Rally’s construction coordination and field support, the project was delivered safely, on time, and under budget.
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