Design, Fabricate and Install Solvent, Thermal Oxidizer, Caustic, Hydro Blasting Access & Steam Lines

Overview

Pructon was engaged by Northern Oil to design, fabricate, and install critical infrastructure components at their Gladstone facility. This project involved the installation of a new DN600 stainless steel solvent pipeline, enhancements to the thermal oxidiser system, caustic lines, hydro blasting access, and steam lines. The objective was to improve operational efficiency, safety, and environmental compliance while reducing costs.

Scope of Work

• Solvent Pipeline: Designed, fabricated, removed, and installed a new DN600 316 stainless steel solvent pipeline and all necessary supports. Pructon collaborated with Northern Oil to redesign the original DN900 pipe down to DN600, addressing issues of stress and poor design that led to the previous piping's failure.
• Thermal Oxidiser: Fabricated and installed 253MA high-temperature stainless steel vapour nozzles for the thermal oxidiser unit, which required confined space entry. Additionally, three 316 stainless steel seamless pipelines were created to connect the nozzles of the thermal oxidiser to the condenser unit.
• Scope Included: Pructon designed and installed new flame-arresting units to prevent flashbacks from the thermal oxidiser unit from travelling through the pipework, which could have caused significant plant damage. This initiative enhanced safety and reduced odours on-site. Furthermore, new vapour lines were installed to facilitate the removal of vapours from ground level, enhancing the safety of on-site personnel.
  • Supply of pipe supports
  • Installation of 3 x flame arresting units
  • Installation of 3 x control valves
  • Installation of 3 x double block and bleeds
• Caustic Lines: Designed, fabricated, removed, and installed a 316 stainless steel caustic pump, pipelines, and supports. This upgrade enabled increased caustic flow to various areas of the site, thereby enhancing production capabilities.
• Hydro Blasting Access: Designed, fabricated, and installed DN250 hydro blasting inspection points on carbon pipes across the site. This allowed the hydro blasting team to access and clear blockages without entering confined spaces.
• Steam Line: Designed, fabricated, and installed a new 2" carbon steam line and supports throughout the processing plant. This installation was aimed at increasing steam flow to all pumps on-site and enabled the client to recycle their condensate for reuse in the process.
• Design of Pipework: 
  • Off-site fabrication completed in our Gladstone workshop
  • Demolition of redundant pipework and structural steel
  • Installation of new piping and structural steel
  • On-site pressure welding of carbon and stainless steel pipes

Outcomes and Benefits

• Improved Safety: The installation of flame arresting units and enhanced vapour lines significantly increased safety by mitigating the risks associated with flashbacks and vapour exposure.
• Operational Efficiency: Upgraded caustic and solvent lines increased production efficiency, while the new steam line enhanced the performance of on-site pumps.
• Cost Savings: The redesign of the solvent pipeline reduced supply and fabrication costs, leading to a more economically viable solution for the client.
• Environmental Compliance: The project addressed environmental concerns by decreasing odours on-site, contributing to a safer and more compliant operational environment.