Project Overview

During an inspection, an in-service tailings line was found to be very close to failing due to the combined effects of corrosion and erosion. The Client required the complete design and construction of 300 metres of NPS 18 carbon steel bypass piping in less than four weeks. Rally responded to this critical situation by working seven days a week to engineer a solution as quickly as possible. Final drawings were issued for construction within 15 days of project kick off. Despite the extremely tight timeframe, all Client risk management processes and best engineering design practices were followed. A HAZOP was conducted to ensure the integrity of the process design, and 3D modeling was done to facilitate operability and constructability reviews. Rally also provided support for material procurement and piping fabrication work.

Tailings Line Bypass main Tailings Line Bypass first

Scope of Work

Rally worked with the Client’s projects and operations personnel to review and refine the scope. Rally defined the basic process requirements, revised the P&IDs, facilitated the HAZOP, completed piping layouts, analyzed the piping stresses, and engineered the structural supports and anchors for the final routing. Rally also supported the fast-track material procurement and fabrication activities, issued engineering work packages (EWPs) to the fabricators, and provided RFI and construction support.

Detailed Deliverables

  • Developed 3D piping and 3D civil models to support the design.
  • Completed a stress analysis of the piping system including pump nozzle loads and piping constraints (i.e., anchors and guides).
  • Facilitated a process hazard assessment (HAZOP).
  • Facilitated a 3D model and constructability review.
  • Developed a bill of materials to quickly procure materials.
  • Developed drawings for pipe spool pre-fabrication.
  • Issued two mechanical / piping EWPs.
  • Issued two civil / structural EWPs.
  • Registered the changes to the original pressure piping design with the provincial authority.
  • Provided home office RFI support.

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