Project Spotlights - Maintenance

Module Floor / Roof Replacement
Project Description: Brindley Engineering is part of a team of companies tasked with replacing and reinforcing a series of composite deck concrete floors on modular structures.
OwnerName: Consortium of Companies
Project Location: Prudhoe Bay, AK

Introduction

The facility was experiencing severe concrete deterioration in their metal deck and concrete composite floor systems at a modular plant that services the North Slope Oil Field. The deterioration was allowing water to penetrate and corrode the underlying pan decking and structural steel. In addition, improper equipment support was transferring cooling fan vibrations to the concrete floor, causing further damage.

Project Scope

The scope of Brindley Engineering’s role on this project included: Engineering Management, evaluating the existing conditions, designing specific repairs for each module, designing an Environmental Control System for placing concrete in arctic conditions, researching and procuring materials, vibration mitigation, pipe stress analysis, on-site field engineering support and hands-on quality control throughout all construction phases. During each construction phase, occurring during module turn-arounds, one to three floors were replaced, sometimes simultaneously over a one to two month period.

Project Challenge

The composite deck floors experienced a unique set of design challenges due to the fact that they were exposed to high temperatures from below, by acting as a roof over large compressors, while also serving as a floor to help support equipment and piping above in an area directly exposed to arctic temperatures known to drop below negative 50° F. The plant is located on the coast of the Arctic Ocean, with floors elevated 60 feet above grade. Although the majority of construction occurred during the summer months, in some cases construction was required during the dead of winter. Due to the remote location of the plant, the team had to plan carefully for any discovery work or other challenges that may arise during construction to guarantee fast, reliable solutions would be available on-site.

Project Solution

Repairs consisted of total replacement and reinforcement of the lightweight 6” thick concrete floors, new metal decking and 8” thick normal weight reinforced concrete. In order to make this possible, the underlying building structures typically required reinforcement and process piping had to be shored while supports were replaced. To avoid reoccurring damage to the new concrete floor, cooling fan vibration stiffening systems were designed and installed prior to floor demolition. These systems consisted of a series of structural steel members designed to transfer vibrations to the building’s main structure and then to the ground rather than directly to the concrete floor.  To overcome the climate challenges, the team developed a temporary climate controlled structure that would allow steel coatings and other temperature sensitive materials to be applied as well as to pump and pour concrete, in the same area where the lowest temperatures in the United States have been recorded with less than 15% average relative humidity.

Project Results

The Team has successfully replaced floors in six modules, punctually and on budget, without any major incidents. All design and construction on this project was conducted under some of the industry’s most stringent specifications and safety guidelines and were completed within limited turn-around timeframes. Based on the quality of the final product, a fine safety record, and meeting project control requirements, more modules are planned.

 

Stats

Square feet of floor demolished: 14,859
Square feet of pan decking replaced: 14,859
Cubic yards of concrete poured: 319
Square feet of concrete floor coated: 14,859
Tonnage of steel installed: 32.3
Number of pipe supports replaced: 41
Coldest Temerature recorded: -83 deg F (wind-chill)

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Tunnel Project
Project Description: Large diameter corrugated pipe tunnel shoring.
Client Name: Undisclosed
Project Location: Undisclosed

Introduction

A tunnel was constructed of large diameter corrugated pipe that acts as a vehicle passage between operating areas of a tank farm. This tunnel was located directly under a roadway that had a significant amount of heavy truck activity. Due to age and increased loading, the corrugated pipe has large local deformations and the roadway is seeing significant cracking. The client consulted with Brindley Engineering to provide a shoring system to ensure the safety of the tunnel.

Project Scope

The primary scope of the project was to address the safety issues of the tunnel and prevent more significant defects of the corrugated pipe. The secondary scope was to monitor the tunnel and roadway conditions on a scheduled basis to develop a permanent repair design that would allow vehicular traffic through the tunnel.

Project Challenge

A major challenge to this project was developing an immediate repair that was cost efficient to the client and easily constructible. The repair had to be implemented almost immediately.

Project Solution

Brindley Engineering modeled the corrugated pipe using Ansys™, finite element analysis software, to determine where critical stresses existed. Structural steel crosses were designed and detailed with the final repair deliverable being calculations and engineering drawings, complete with bill of materials and sequencing, to expedite the fabrication process. A permanent shotcrete/reinforced steel repair was designed shortly thereafter.

Project Results

The project was executed seamlessly from start of design to end of construction in less than 3 weeks with zero revisions. Further evaluations have shown no significant movement post-repair.



Steel & Fireproofing Maintenance
Project Description: Steel and Fireproofing Evaluation and Engineering for Replacement
Client Name: Midwest Refinery
Project Location: Midwest

Introduction

During the implementation of a reliability program, a deficiency was found through a scheduled inspection on a critical unit at this Midwest refinery. The deficiency was found under several of the main load bearing beams supporting critical equipment and required emergency repair.

Project Scope

The main scope of the project was to inspect and analyze the condition of the steel and fireproofing of the entire area. It was imperative to perform these inspections/repairs while the unit was active and operating throughout the entire time. Also, access had to be maintained throughout the entire construction area for operations personnel due to the high importance of the unit.

Project Challenge

An initial challenge on this project was to develop a solution and step-by-step repair process, while maintaining access and safety to the unit and its personnel. One of the main load bearing beams was supporting a spring support that needed to remain in service in order to accommodate the changes in temperatures of the gas lines. The main challenge was to keep this support in service during the replacement of the beam.

Project Solution

The primary solution was to utilize the main girder supports 3 levels below to support inverted spring support as a temporary support for the main load bearing beam being replaced. This was accomplished by performing multiple calculations and creating a configuration innovative enough to fit thru the active structural/system.

Project Results

After the inspection was complete more than one member were found deteriorated and needed repair and/or replacement. This was accomplished after the temporary support was placed on the main load bearing beam and all main live loads were release from the system. Multiple members were changed properly and access was granted throughout the entire construction sequence. No revisions and or modifications were needed throughout the entire project.



Pipe Stress Analysis
Project Description: Pipe stress analysis to support Owner's maintenance programs.
Client Name: A Consortium of Companies
Project Location: Prudhoe Bay, Alaska

Introduction

A maintenance program at one of the Owner's facilities required piping to be analyzed for current stresses and nozzle loadings, then compared to various different construction loading and operational scenarios as well as progress support failure analysis. This was done to design the structural repairs required, sequence the work, understand the risks, and mitigate the potential risks to improve the safety and constructability of the execution.

Project Scope

Utilized existing isometrics to conduct field walkdowns for verification of pipe routing, equipment and support locations, and support types. Analysis was provided for the piping system in compliance with ASME B31.3 and API 661 standards to determine the maximum nozzle loads, pipe support loads, and pipe stresses while the piping was to be temporarily supported. The loads and stresses were compared to industry/vendor allowable loads and code allowable stresses, respectively, to ensure design/code compliance during the project.

Project Challenge

As-built equipment had little to no information available.  This made obtaining critical information such as weights of components and center of gravity, needed to accurately model concentrated loads, difficult.  Further, the piping varies in sizes up to and including 28 inch lines containing hydrocarbon at operating pressures greater than 3600 psi.

Project Solution

Using data files and industry contacts from our experienced pipe stress analysts, similar equipment was identified and sound estimates used to properly qualify the loads and stresses.

Project Results

Brindley Engineering provided the support loads and stress reports on time to support all project milestones.  During the process, construction sequencing constraints were identified in advanced and the designs were modified to remove or minimize these constraints while ensuring the integrity of this high pressure system. 

 

Stats

Thus far, modules containing about 560 lines, 900 supports, and 15,000 LF of pipe have been analyzed.

Refinery Turnaround
Project Description: Planning for a Refinery Turnaround
Client Name: CITGO
Project Location: Lemont, IL

Introduction

Due to the success of previous turnarounds for this client, Brindley Engineering returned to help with another Turnaround (TAR) Planning and Execution project, a specialty service of Brindley Engineering.

Project Scope

Brindley Engineering provided CITGO with Mechanical Engineering Support, which included Reliability Reviews on equipment and piping, producing Requisition Packages, Technical Guidance, Piping Package Assembly and Approval of Routing Sheets and Isometrics, Defining Scope of Work, and Gasket Selection Calculations.

Project Challenge

One of the perks with working as a reliability engineering company in a refinery is the necessity of going out in the field. Pipe routing, equipment installation, and quality assurance are some of the many jobs a reliability engineer cannot do sitting in an office alone. The TAR at CITGO took place during the summer and one of the challenges we all faced in the refinery was the heat. Heat from the sun, heat from equipment, and heat from our own body from climbing up to 300 feet in full body Fire Resistant (FR) clothing.

Project Solution

Brindley Engineering takes pride in hiring highly motivated and dynamic individuals and we promote a safe and fun atmosphere, and this is what sets us apart. Despite the heat, the unexpected problems, and the mentally challenging questions, we all adapt to overcome.

Project Results

CITGO Turnaround started on time and was completed in about 6 weeks. All reliability packages were completed by start of the Turnaround.

 

Stats

Reviewed over 450 pipe routing packages 
Reviewed over 60 requisition packages 
Reviewed over 15 scope of work packages.