Reinforcement of existing structures

Reinforcement of existing structures in plant revamping project is the crucial item to achieve the success of the project while the existing plant is running. The time frame required to perform civil and structural works during plant shutdown is the key to decide if revamping activities of the plant are feasible.

Casale has proven experience as an international world-class Licensor and EPCC engineering contractor, for the realization of revamping project.
Casale civil engineers have right experience, competences and background, not only to cope with the execution of the mentioned projects but in general to cope with any kind of technical challenge related to reinforcement and revamping of existing structures.
As EPC contractor Casale is able to design supply and construct the reinforcement of existing structures to accommodate the plant revamping while the existing process plant is in operation.
The main goal of Casale is to find the right solution that will balance between time for plant shutdown and construction cost.

Reinforcement of existing foundation to accommodate the new loads

More specifically either for new plants or revamping projects Casale can become the focal point for the Customer, handling all the activities of different technical disciplines:

Machinery (e.g., assessment of existing machines issue of all technical specifications necessary for inquiry and purchase, selection of preferred supplier, review of technical documentation, technical coordination of all the other involved disciplines, site assistance);
Piping & Layout (e.g., revision of plot plan, new pipe routing, line modelling, stress analysis, laser scanning of existing facilities to be uploaded in the 3d model.);
Instrumentation (e.g., specification of new control valve and recycle valve, integration of new system with existing DCS and ESD, definition of minimum requirements for critical and special instruments);
Civil & Structural (e.g., design of foundations and steel structures, check of existing structures and design of reinforcement to support new loads and equipment);
…and much more!

Casale is therefore able to re-design the plant with the guarantee of the perfect balance among investment cost, service life and process flexibility.

The scope of engineering services covered by Casale can be tailored on Customer requests, involving also local construction contractors.

Case History

Context

Reinforcement of existing Urea bulk hall to support new conveyor gallery

Backgroud

As part of the project new Urea plant 2200 MTD for an important Russian Customer, Casale along with Customer identified that existing urea bulk hall building and train loading areas where suitable to accommodate the additional urea product produced by the new plant.
This necessity was confirmed by the overall assessment made by Casale on the CAPEX/OPEX aspects of the revamping, therefore Casale decided to maintain the existing Customer facilities and to build only a new conveyor gallery to deliver the new urea product by reinforcing the existing structures.

Erection of new steel frames inside existing urea storage

Constraints

Space: the new conveyor gallery to be installed inside the existing plant with all the constrains related to constructability and safety distance to existing facilities;
Existing structures condition, the plant existing structures were built back in the 60s with several issues related to maintenance;
Engineering: important efforts were spent to defines the new routing and configuration of the conveyor gallery. Casale followed all the below aspects and more:
- Inspection of existing structure and foundation with structural checks;
- Development of new conveyor gallery routing to respect all the constrains of Russian laws and operation requirements;
- Study the constructability of the new gallery and the reinforcement of the existing structures with the plant in operation.

Erection of new transfer tower above existing storage

Solution

New two steel frames, measuring 54 meter wide and 22 meter high, were installed inside existing bulk hall building to support new conveyor gallery that were installed as preassembled steel structural modules to the design location.

Result

New foundation to support the frames were designed between all existing foundation and utilities, the two new steel frames have been installed inside existing storage building while plant was in operation with only a reduction of urea storage capacity of 30%, conveyor galleries designed as preassembled steel structure modules.