In the world of industrial services, where the stakes are high and precision is key, there's a constant drive for innovation, safety, and efficiency. We recently undertook a significant large bore valve replacement project in Brunswick County, showcasing these very principles in action. Let's dive into how this complex project was executed with remarkable attention to detail, safety, and planning.
The Challenge: Large Bore Valve Replacement
ARC Energy Services was tasked with the significant responsibility of replacing six valves across three units in a plant. Three 14” Non-Return Valves (NRVs) and three Flow Block Valves (FBVs) needed to be cut out and replaced. The challenge was amplified due to the locations of these valves, the weight increase of the new valves, and the strict safety measures that had to be adhered to, ensuring the safety of personnel and plant equipment. The intricacy of this project required careful planning, advanced rigging practices, and meticulous execution.
Ensuring Stability and Structure
Before the valve removal process, temporary restraints were installed to prevent piping from shifting, ensuring the stability of the plant structure. Permanent steel was also installed to maintain the structural integrity, accounting for the weight increase of the new valves.
Valve Removal and Installation
Valve removal was done with great precision, employing split frames to cut out the valves and prepare the existing piping. Every step was done with care, including attaching multiple points to ensure control and stable flight during lifting.
When it came to installing the new valves, advanced rigging practices were used to rig up the new valves to the crane and level them. Once the old valves were cut out, the new ones were carefully lifted up and placed, ensuring their position fit perfectly with the existing piping.
The Welding Process
The welding process was of utmost importance, with stringent guidelines to follow, especially considering the Gr 91 material used required pre-heating before welding. There was a series of steps, from fit-up and purge, to the root pass, and finally, stick welding to fill and "cap" the weld joint.
Testing and Inspections
Every valve was subjected to Phased Array Ultrasonic Testing (PAUT) before and after Post Weld Heat Treatment (PWHT), which ensures the acceptable hardness of the weld material. Magnetic Particle Tests (MT) were conducted to ensure no surface defects after the heat treatment process.
Wrapping Up
Once the valves were installed, tested, and approved, the project was in its final stages. All temporary structures were removed, areas cleaned, and tools were removed from the site. Client walkthroughs were conducted to confirm the project was executed as outlined in the contract.
Lessons Learned
This large-scale project reinforced the importance of skilled manpower, proper planning, anticipating worst-case scenarios, and stringent supervision. Moreover, housekeeping emerged as a crucial factor, contributing to both safety and efficiency.
Conclusion
Upon completion, this project epitomized ARC Energy Services' commitment to safety, quality, time schedule, and budget. We strive for excellence in every aspect of our work and uphold the highest quality standards. This project not only strengthened our capabilities but also reinforced our commitment to delivering results above and beyond our client's expectations.
The success of the Brunswick County large bore valve replacement project underscores the power of planning, precision, and persistence. At ARC Energy Services, we are continuously innovating, refining our practices, and setting new benchmarks in industrial services.