Rally worked with the Client to develop a Design Basis Memorandum (DBM) which defined the scope for this project. The pipe rack was segregated into six sections, each with an optimized repair strategy. Sections that were salvageable were reinforced and repaired, while other segments were completely replaced. Stress analysis was carried out for the piping, and repairs were made to the underlying foundations.
Key project scope items included pipe rack design, a new pipe bridge rail crossing, modifications to existing steel structures, and relocation of existing facilities.
A brand-new pipe bridge spanning the existing rail tracks was engineered in the space around the existing bridge. This made new construction possible without interrupting the existing piping or electrical services. Once the new rack was carrying the load, the existing rack was dismantled in situ.
The project also corrected piles to prevent further frost heaving and jacking, added pipe shoes, and upgraded spring hanger hardware to eliminate failing supports.
All field work was successfully executed while the plant remained in operation.