Project Overview

The project consisted of the installation of new piping, cable trays, cables, structural steel pipe racks, concrete vaults, and an underground pipe rail crossing in support of a refinery expansion project. The project also developed piping layouts and identified tie-ins for a new wastewater treatment plant.

Pipe Racks, Piping, Underground Rail Crossing main Pipe Racks, Piping, Underground Rail Crossing first Pipe Racks, Piping, Underground Rail Crossing second

Pipe Rack Scope of Work

Rally’s scope of work included the engineering of a new two-tiered, 20 ft wide x 1300 ft long structural steel pipe rack. Rally also designed all of the associated process / utility piping and electrical / instrumentation cabling. New concrete enclosed vaults and a 200 ft long underground rail crossing with valve isolation stations were engineered.
In support of this scope, Rally optimized pipe line sizes by performing hydraulic simulations and calculations. Rally’s scope of work ultimately included piping and tie-ins for a new wastewater treatment plant.

Rail Crossing and Concrete Vault

The concrete vaults were designed to accommodate eighteen pipes, in four 42-inch casings, bored in place under the main rail crossing. Two additional 42 inch casings were installed to carry cable and cable trays. The vaults were designed by Rally with fully enclosed and ventilated safety compartments, hazard sensors, and alarms to segregate electrical, process and utility piping.
The design accounted for potential leakage due to piping corrosion and storm water flooding. Because the casings were installed above frost line, and up to five lines were installed in each casing using custom pipe spacers, our design relied upon extensive piping stress analysis to safely engineer the loading of the heat traced & insulated multi-pipe spacers.

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