BP Naphtha Splitter Column
ASI WA Steel Awards 2008
Steel Fabricators Award
Introduction from Liam Donley
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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
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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.
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Design carried out to AS1210, AS4100 &
AS1657 incorporating all current amendments
and BP’s own stringent specifications and
standard details.
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In-House FEA analysis of critical areas.
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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
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Increased value proposition to this important
Client via complete end-to-end service, from
engineering design through to delivery.
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Streamlined and integrated workflow which
provided cost and schedule efficiencies.
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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.
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Refined interface with the associated civil,
piping, electrical and instrumentation works.
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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
• Rolling saddle rings
• Reinforcement & insulation
retaining rings
• Shell rolling
• Rolling angle iron
•Sub-arc welding of shell plate
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Work in Progress - February
• Formed end cap
• External saddle rings
• Flux cored vertical up weld
• Head nozzles in place
• Loading shells
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Work in Progress - March
• End cap to shell
• Joining the shells
• Formed and welded tail lug
• Inner saddle ring
• Internal tray supports
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Fabrication Support Issues
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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
• Cordon off and encapsulate work
area for blast & paint
• Blast clean to AS1627,Part 4
Class 3 blast profile 35 to 65
microns
• 3 coat paint with:
•Interzinc 86 to 75 microns
•Intertherm 50 to 25 microns
•Intertherm 50 to 25 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 Cladding
100mm Rockwool Insulation
1.2mm Corrugated SS
and 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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