Project Overview

Buried pipelines for 24 different commodities were in service for 50 years or more. Many of these lines conveyed the refinery’s main products to their sales tanks. Inspections and maintenance of these piping systems were costly, and the risk of a high-consequence failure of one or more lines due to corrosion increased with each passing year. A project was created to reconstruct the buried piping above grade on a new pipe rack.

Buried Pipe Replacement main Buried Pipe Replacement first Buried Pipe Replacement second

Scope Development

Rally worked with the Client to develop a design basis memorandum (DBM) which refined the scope of the project. The team then progressed into detailed engineering and eventually construction support. Key project scope items included pipe rack design, piping layout and tie-in strategy, earthworks and grading improvements, a new bridge crossing, modifications to existing steel structures, and relocation of existing facilities.

Detailed Deliverables

The primary pipe rack was designed as a single module that was fabricated offsite. Modularization of the pipe rack reduced overall cost and shifted work hours from the field to a lower-risk shop environment.
Staggered piping tie-ins to connect new rack piping with existing lines were scheduled for turnarounds and other planned outages over a three-year period. Rally collaborated with the Client’s stakeholders to optimize the tie-in plan and produced construction work packages (CWPs) targeted to each tie-in opportunity.
Significant improvements were also made to the groundwater drainage and local power distribution lines in the project area.

Download PDF