The investor reported a problem of regular cracking of welds in the high-pressure steam pipeline and leaks in fittings, which resulted in regular emergency shutdowns of this and related production installations using high-pressure steam. We were commissioned to analyze the phenomena occurring in the installation, identify the problem and present a solution leading to increased reliability of the installation.
As part of the research and development work, the system operation was analyzed and a calculation model was created based on measurements of the geometry of five main pipelines and auxiliary piping, using specialist software. A 3D model of the existing installation and P&ID diagrams were also prepared. Based on the work carried out, it was possible to identify the causes of the occurring phenomena and develop a solution that eliminates the reported problems. Analysis of the strength model allowed the development of a new method and location of supports for problematic pipelines. Analysis of the installation operation led to the selection of a new boiler water injection valve with parameters adapted to the needs of the installation. A detailed inventory and 3D model of the installation were the basis for the preparation of detailed technical documentation on the basis of which the pipeline modernization was carried out.
Increased reliability of the installation minimized the number of emergency stops, limiting the financial losses resulting from them. Reduced frequency of failures also improved the safety and comfort of the crew operating the object.
