"This Brownfield Project demonstrated our capability in solving problems that allowed us to maximise the re-use of existing infrastructure and facilitate installation with no impact on plant operations."
Geoffrey Constable
Projects Director
Detailed Design
Onshore Gas
18 Months
TIC $650k
We were engaged for this project at the beginning of the FEED stage. The project progressed through FEED and then detailed design, installation and commissioning.
The project brief was to determine the best strategy for either a 1) repair or 2) replacement of the two
pumpsets (one 250 kW electric powered unit, one 300 kW diesel powered unit), which provided firewater to the facility. . The pumpsets,
while still operational, had several issues including significant internal corrosion to the impeller and casing, and the engine on the
diesel-powered pump was reaching end of life.
As an initial step, it was important to understand the root cause of this corrosion so that any newly installed pumps would not experience the same problem. The understanding of this problem included taking samples of the source of the fire water for the facility. This water sampling confirmed the presence of microbes capable of causing microbial induced corrosion, which was determined as the cause of the corrosion.
With all the background research undertaken to understand the corrosion issues, and the existing pumpset maintenance issues, we took to market a bid package including the appropriate datasheets and specifications for vendors to quote. The bid package included a requirement for a suitable internal coating of the pumps (to prevent further internal corrosion) and options for either a full rebuild or replacement of the diesel engine and replacement of the pump skids, along with associated electrical/control system updates. The package also included a requirement to reuse the existing pump support plinths, a large cost saving for the project. To achieve this objective required careful attention to detail in the final design of the pump skids that all bidders had to consider.
Following receipt of the bids and the technical bid evaluation, we were able to complete an analysis showing our client the various cost and risk considerations for their consideration. Based on this analysis, a decision was then made to procure the two new pumpsets, one containing the diesel engine and the electrical/control system, and the other with only a new pump (as the electric driver had been confirmed as suitable for re-use).
After award to the preferred vendor we managed all the vendor data review, technical queries and FAT for the pumps. As part of the project award it was critical to manage the final dimensions and layout of the new pumpsets, to ensure they could be retrofitted onto the existing support plinths, that the existing electric motor could be accurately mounted on the appropriate skid, and to minimise rework of the pump suction and discharge spooling.
In parallel with managing the vendor data we developed the necessary installation scope of work documents and commissioning procedures which were used by the client during these phases. These documents considered and managed the options for completing the changeover of pumps with minimal interruption for the site.
Due to the careful thought, planning and monitoring undertaken, the project was successfully completed as expected, with the existing plinths re-used (a significant cost saving for the project), electric motor and pipe spooling matched up and a staged replacement of the pumpsets undertaken, which ensured at least one fire pump was available at all times. Final commissioning of the pumps then proceeded as planned.