Case Study
Reformer Unit Turnaround Equipment Replacement
Challenge:
A large refinery needed various equipment replaced sooner than expected due to corrosion. For each of the replacement projects, there was an increasing risk of reaching end of asset life-cycle prior to the planned replacement scheduled. The replacements were originally contemplated for a future turnaround, however, it was apparent that the work needed to execute the replacements would need to be ready for an upcoming turnaround schedule.
Solution:
Valdes responded to this challenge and helped the client prepare project scope for pre-turnaround or turnaround implementation and expedited procurement and replacement of various replacement projects, including a hydrotreater separator drum ($5.4 MM), gas centrifix replacement ($1.5 MM), debutanizer tower ($10 MM), and heat exchangers ($5 MM).
Impact:
Valdes accomplished the design objectives and delivered timely equipment procurement support and TAR contractor work scopes for the various replacement projects so that the client met the deadlines required of the upcoming TAR schedule.
SERVICES:
Process
- Simulation & Modeling
- Studies
- Technology Evaluation & Selection
- Front-End Project Development
- Process Optimization
- PFD/P&ID Development
- Heat & Mass Balance
- Equipment Selection & Specification
- Process Equipment Evaluations
- Relief Device & System Analysis
- Utility System Design & Evaluation
- Process Control Design
- Process Scope Development
- Effluent Handling System Design
Mechanical
- Facility Design & Plant Layout
- Equipment Selection
- Material Handling & Dust Control Systems
- Rotating Equipment Sizing & Specification
- HVAC
- Fire Protection & Detection
- Plumbing
- Fluid Heat Tracing
- Blending & Mixing Systems
- Heat Exchanger Selection
- Plant Utilities
- Industrial/Hygiene Ventilation
- Equipment & Piping Specifications
- Field Walkdowns/Constructability Review
- Pressure Vessel Design
Piping & Plant Layout
- Piping Layouts
- General Arrangement Drawings
- Line Studies
- Piping Isometrics
- Equipment Arrangements
- Vessel Nozzle Orientation
- Vessel Platform & Ladder Layout
- Underground Piping Layout
- Process & Utility Piping Design
- Construction Field Support
- High Definition Laser Scanning & 3D Modeling/Design
Pipe Stress Analysis
- High-Energy Piping Surveillance
- Design/Sketch Drawings
- ASME Code Calculation
- Nozzle Finite Element Analysis
- Vessel/Heat Exchanger Design
- Vessel/Heat Exchanger Modifications & Alterations
- Vessel/Heat Exchanger Re-Rating Package
- Inspections
- Piping Engineering
- Pipe Hangers/Supports
- Pipe Loading Conditions on Equipment
- Surveillance Report
Electrical
- System Analysis (SKM Power* Tools):
- Load Flow
- Short Circuit
- Overcurrent Coordination
- Arc Flash
- Transient Stability
- Utility/Industrial & Transmission/Service Substations
- Industrial Power Distribution:
- Power Transformers
- Low/Medium Voltage Switchgear
- Motor Control Centers
- VFD Installations
- Protective Relay Settings, Generators & Distribution
- Diesel Generator and UPS Systems
- DC systems
- Grounding & Lightning Protection
- Lighting
- Equipment & Raceway Layout Drawings
- Wiring Diagrams & Schematics
- Electrical Heat Tracing
- Area Classification & Code Compliance
Instrumentation & Controls
- PID Controller Application & Specification
- Instrument Selection & Specification
- Instrument Index & I/O Lists
- Control Valve Sizing & Specification
- Instrument Loop & Interconnection Diagrams
- Smart Plant Instrumentation/INtools
- HAZOP Participation
- Control Panel Design Instrument Location Plans
- Installation Details
- Instrument Commissioning
- Safety Instrumented Systems (SIS) Implementation*
- Engineering & Design in Accordance with ISA84 & IEC-61511 Standards
- HMI, MMI, & SCADA Functional Specifications
- Operator Interface Specifications
- Operator Usability Studies
- PLC & DCS
- Specification Selection
- Functional Descriptions
- Ladder Logic
- Hardware Interface
- System Architecture Drawings
- HART & Foundation Fieldbus
- Control Room Layout & Design
- Control System Training Manual
- Site/Factory Acceptance Testing
Civil
- Site Development/Selection
- Storm/Sanitary/Oily Water Sewers
- Stormwater Management/Permitting
- Grading/Drainage
- Containment Design
- Roadway & Pavement Design
- Underground Utilities
- Railroad Layout
Structural
- Retaining Structures
- Building Frame Design
- Seismic Analysis
- Foundation Design
- Steel Structure Design
- Vibration Analysis
- Concrete & Steel Restoration
- Inspection/Assessment/Reinforcement of Existing Structures
- Structural Engineering Certification (SE)
Laser Scanning & Surveying
- Pre-Design Surveys
- Utility Mapping
- Structural Steel Surveys
- Topographic Maps
- Line & Grade Measurements
- Foundation Surveys
- As-Built Drawing Development
- Vessel & Equipment Surveys
- Spool Verification
Project Controls
- Planning & Scheduling
- Cost Management
- Performance Measurement
- Earned Value Analysis (EVA)
- Cost Estimating
- Key Performance Indications (KPI)
- Metrics & Tracking
- Risk Analysis
- Change Order Administration
Project Management
- Fast Track Project Execution
- Formal Project Communication Methods
- Strategy Development
- Financial Management
- Critical Path Schedules
- Project Risk Assessment & Risk Mitigation
- Cost Tracking & Reporting
- Cost Estimating
- Feasibility Analyses to Guide Strategic Business Decisions
- Commissioning/Start-Up Planning