BP Naphtha Splitter Column

ASI WA Steel Awards 2008

Steel Fabricators Award

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Introduction from Liam Donley

• Good evening fellow engineers. My name is Liam Donley and I am the Senior Project Manager at the United Group Resources Kwinana Fabrication facility.

• In August this year, BP commissioned a new Naptha Splitter at the BP Kwinana Refinery. The commissioning of the Naptha Splitter was the culmination of some 18 months work for United Group Resources.

• By way of history, in March 2007, United Group Resources tendered for BP Kwinana’s Naphtha Splitter Column project. BP conducted the tender process utilising global procurement channels, and in May 2007 United Group Resources were awarded the contract on the basis of local presence, capability and dependability on quality and schedule deliverables. United Group Resources provided engineering design, detailing, supply, fabrication and delivery to site of a new Naphtha Splitter Column.

• The BP Naphtha Splitter column is the largest single fabricated vessel United Group Resources has ever fabricated. The project was completed on schedule, with zero health and safety recordable injuries and zero quality issues.

• United Group Resources provided in-house engineering design and detailing of the Naphtha Splitter Column. The design model was developed using the Tekla Structure (XSteel) shop detailing software package enabling seamless interface and transition between the engineering design and detailing phases. The smooth progress of the entire design and fabrication project was possible due to the integrated engineering, fabrication and construction delivery model provided by United Group Resources. Design of the Naphtha Splitter Column also involved close liaison with the balance-of-plant design engineers (Worley Parsons) in numerous 3Di design review sessions. This collaboration allowed refinement of the interface with the associated civil, piping, electrical and instrumentation works.

• The 64m high x 4.5m diameter pressure vessel weighs 308 tonnes and involves a very complex interaction of internal process trays, baffles, numerous piping nozzles, and external access platforms, ladders & walkways. Due to the immense size and weight of the splitter column, United Group Resources constructed the shell of the vessel in 3m x 4.5m diameter sections in its Kwinana workshop. This modular construction method was used to maximise resources and optimise schedule compliance.

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Engineering Design & Modelling

• 65m high x 4.5m dia Class 2A pressure vessel weighing 308t and involving a complex interaction of internal process trays, baffles, numerous piping nozzles, and external access platforms, ladders & walkways.

• Design carried out to AS1210, AS4100 & AS1657 incorporating all current amendments and BP’s own stringent specifications and standard details.

• In-House FEA analysis of critical areas.

• Engineering model developed directly in Tekla Structures (XSteel) in-house at UGL Resources offices in the Perth CBD.

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Engineering Design & Modelling

• Increased value proposition to this important Client via complete end-to-end service, from engineering design through to delivery.

• Streamlined and integrated workflow which provided cost and schedule efficiencies.

• Close liaison between the Client’s team, the balance-of-plant design engineers (Worley Parsons) and the fabrication team, in numerous 3Di Design Model Review sessions.

• Refined interface with the associated civil, piping, electrical and instrumentation works.

• Fabrication deliverables produced directly from the approved 3Di Model.

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Workshop Preparation – December/January

• Clearing and preparing

the 3600 sq.m workshop

• Laying trolley tracks. Laser

aligned, embedded and

cemented into flooring

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Work in Progress - January

• Flat bar sectional rolling • Reinforcement & insulation retaining rings

• Rolling angle iron

• Rolling saddle rings • Shell rolling •Sub-arc welding of shell plate

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Work in Progress - February

• Formed end cap • External saddle rings • Head nozzles in place

• Flux cored vertical up weld• Loading shells

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Work in Progress - March

• End cap to shell • Formed and welded tail lug • Inner saddle ring

• Joining the shells • Internal tray supports

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Fabrication Support Issues

• Workshop Handling on custom built roller trolley

• Special support system for 1,000+ tonne hydro test loads

• Custom stiffening collar for jacking and transport conditions

• Extensive lifting study and stiffening arrangements.

• Custom built platforms for safe access.

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Work in Progress-April

• Joining shells

installing nozzles

•Internal fit out with

trays and baffles

• Dimensional

accuracy achieved

with 17,000 bolts

fitted without

requiring any rework

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Work in Progress-May

• Internal fit out of ASTM A240 410S

stainless steel trays & baffles

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Work in Progress-May

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Work In Progress-June

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Hydro test preparation

• Installation of the

support beams grouted

to the floor and welded

to the stiffening rings

side & underneath to

distribute and support

the total projected weight

of 1380 tonnes after

filling the column with

water to conduct the

Hydro test.

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Hydro test

•Filling the column with

water to Hydro Test to

a pressure of 750 kPa

which was maintained

for a duration of 1.5

hours without a weld

failure

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Blast, Paint & Installation of Jacking Frames

• 3 coat paint with:

•Interzinc 86 to 75 microns

•Intertherm 50 to 25 microns

•Intertherm 50 to 25 microns

• Cordon off and encapsulate work

area for blast & paint

• Blast clean to AS1627,Part 4

Class 3 blast profile 35 to 65

microns

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Insulation & Cladding

• Apply fire retardant

to 4m skirt (applied on site)

• Apply internal &

external application

of Chartek-7 to

4m from base

• Skirt: 4mm Chartek-7

and CS GD 250

Cladding

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Cladding Complete

•Insulation and Cladding100mm Rockwool Insulation

1.2mm Corrugated SSand Corrugated Zincalume

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Preparing For Transportation

•Jacking the column up to

allow transportation

•Jacked up to a clearance

of 2.1m

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Delivery

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