Project Overview

This Client’s Refinery had reliability issues with level control valves for the high-pressure hot separator in the Unit. A valve had been recently replaced with a typical style letdown valve; however, this valve and secondary valve continued to have significant reliability issues due to the letdown differential. The Client engaged Rally Engineering to investigate replacing these valves with Masoneilan valve which had been researched by their onsite team. The valves were in a congested area and piping changes were extremely complex.

Replace HP Hot Separator Control Valves main Replace HP Hot Separator Control Valves first Replace HP Hot Separator Control Valves second

Scope of Work

Client requested Rally to develop options for piping and structural supports to a level of a scoping study and provide a +/-30% cost estimate.

Rally completed a significant detailed piping and stress evaluation to ensure confidence in the cost estimate. This extra effort was realized as a cost saving in engineering in the detailed phase.


  • Reviewed drawings / data sheets for the existing valves, supports and stress.
  • Provided complete authenticated CWPs
  • Detailed critical stress analysis
  • Provided construction support
  • TSASK document submission

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