case study: gas turbine pipe modifications
TRANSCRIPT
Consultancy.
Project Delivery.
Innovation.
Case Study: Gas Turbine Pipe Modifications
FEED and Detailed Design deliver the right solution
Client: ~1GW Power Station
Project Background
Upgrades to two turbines required installation of emergency
depressurisation system on each fuel gas line
Tight deadline to design and build modification for planned shutdown
Working closely with construction partner (DeeTech) to ensure
constructability was considered throughout the design
Client had requirements for depressurisation time, hazardous areas,
accessibility, and maintenance
Slam shut-off valves and vent valve already specified by client
Pipework in crowded pipe rack, with no space for installation
Client had no in-house design capability, so must engage a competent
designer
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Engineering Scope
Detailed site survey
Process design, including HYSYS Dynamics validation
Process Safety, including chairing the HAZOP
General arrangement and detailed mechanical & structural design
Complete pipe stress calculations in Caesar II
Complete structural calculations in STAAD Pro
Final design review with client
Full design package Issued For Construction
Deliver P&IDs, hazardous area maps, general arrangement drawings,
isometrics, platform & foundation drawings, pipe support drawings, and
specifications – all issued for construction
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Process Design
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Hazardous area classification
Venting noise calculations
Dispersion modelling
HAZOP
Layout optioneering
Line sizing
Equipment specifications
Design validation (HYSYS)
Trip analysis (HYSYS)
Mechanical Design
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Detailed site survey
Pipe routing design
Existing site obstacles identified
and avoided
Constructability considered
throughout
General arrangements
Initial support and platform design
Pipework isometrics
Pipe Stress Engineering
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New pipe specification (original
site documentation missing)
Pipe supports design
Ensured compliance with
relevant piping standards
Complete CAESAR II calculations
Emergency venting (transient)
mechanical loads
Structural Engineering
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Platform and foundation design
Pipe support steelwork design
Design within confines of existing
steelwork & underground services
Pre-shutdown construction plan
Design in line with existing site
standards and practice
Compliant with ISO standards
Complete STAAD Pro & PROFIS
calculations
Summary
Incorporated design into crowded site – full piperacks, underground
services, and existing steelwork had to be considered throughout
Integration of process, mechanical, civil, and structural engineering led
to an efficient workflow which got the design right first time
Worked in partnership with construction contractor to develop coherent
works plan as intrinsic part of design stage – this allowed for significant
construction prior to shutdown
Fully checked out design with process, stress, and structural calculations
using the latest software tools
Detailed deliverables for construction
Minimal supervision requirement from client
Completed for lump sum, within budget & timescale
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Summary
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Consultancy.
Project Delivery.
Innovation.
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