RMC-12-31 Improving Efficiency/Reliability Through 3-D Planning

Description:

For most jobs in a refinery, the efficiency of the work execution is improved with planning. This planning, however, is almost entirely done spatially in two dimensions. While not all jobs require planning in third dimensions, ignoring the third dimensions can lead to delays and safety risks from overcrowding and clutter. The execution challenge facing our plant was to efficiently replace 16, welded-end, 14” motor operated valves (MOV) and 19, welded-end, 20” MOV’s while repacking 13 MOV’s during a turnaround (TAR). All these valves were located on a common elevated deck at roughly the same elevation. Successful execution of the valve replacements required unique planning perspectives. Adding a dimension to the normal best practice in project planning was the solution. The MOV’s are part of a UOP design Ultraformer regeneration system. The piping system is designed with cold spring, and due to inter-connections, the cold spring in the lines can affect adjacent MOV alignment. Failure to control the cold spring can severely affect the complex piping support system leading to unanticipated stresses in operating or regenerating conditions. An engineering plan that would alleviate rigging congestion while preventing piping mismatch and uncontrolled cold spring was necessary. The engineering solution was to provide a three dimensional analysis of support, rigging, and valve handling while sequencing work to avoid releasing the cold spring in the piping system.