Rally worked with the Client’s preferred heater vendor to run various process simulations of the convection tube bundle. This revealed that the new bundle could be furnished with thicker tubes for longer life without adversely affecting pressure drop or heat transfer.
Rally also developed a construction schedule and a capital cost estimate (CAPEX) during initial scoping. This helped the Client’s project team secure full project authorization.
Material requisitions (MRs) were issued for the new convection section, flue gas duct, and tube-skin thermocouples. Rally closely managed the convection section vendor to ensure that new equipment arrived on site fully inspected and in time for the heater outage.
Construction work packages (CWPs) were produced for the demolition of the existing convection section and ducting, the erection of the replacement equipment, and for the installation of new tube-skin thermocouples.
All project activities – from kick-off to commissioning of equipment – were completed in 10 months, meeting the Client’s accelerated schedule.