Petronet Crude Prover Upgrade – Kendal & Fynnlands Pump Stations

• Remove existing 24” x 150# Crude Prover from Kendal.
• Modify the Kendal Prover.
• Install the modified prover at Fynnlands Pump Station.
• Tie-in of pipe work from the 4-way valve on prover to existing valves.
• Dismantle and remove old prover loop.
• Electrical & Instrumentation installation with SCARDA modifications.
• Modifications and re-casting of Civils
• Prover Loop Dimensions:14m X 24” Piping..

Petronet Secunda Pump Station Upgrade – Mechanical and Civil Works

• Re-elevate Proving unit for consistent piping elevations and ease of valve maintenance.
• Installation of new de-aerators, strainers and valves for dedicated product lines.
• Upgrade to pump manifold, Manufacture and install new base plates, pumps and motors.
• Civil works for upgrade entailed design works, and construction of plinths for new pump set, de-aerators, strainers and bund wall and floor areas.
• Complete piping fabrication and installation including structural works.
• Access to carry out work introducing new equipment to plant is done during shutdown periods in order not to affect operational requirements. The success is thorough planning, preparation and execution.  Doing it right first time.

Petronet Ladysmith Pump Station – Prover Upgrade Project Mechanical and Civil Works

• Construction of new floor and bund area to receive new prover, pumps, and tanks.
• Construction of plinths for prover structure.
• Installation of triple u prover.
• Demolition of existing ram prover and associated equipment.
• Manufacture and install new transfer tanks.
• Installation of new transfer and blending pumps.
• Relocate valves as per P&ID.
• Complete piping fabrication and installation including structural works.
• Access to carry out work introducing new equipment to plant is done during shutdown periods in order not to affect operational requirements. The success is thorough planning, preparation and execution.  Doing it right first time

Natcos Berth 9 Island View Durban – Marine Loading Arm Replacement Mechanical, Civil, E&I Works

• Demolition of old marine loading arms.
• Civil construction works for new marine loading arms.
• Electrical and Instrumentation works to receive new marine loading arms.
• Manufacture and installation of new stainless steel sump tank.
• Installation of new marine loading arms in conjunction with Manufacturer as part of guarantee.
• Complete piping fabrication and installation including structural works.

Transnet Pipelines Witbank Pump Station – Telephase 2 Upgrade Mechanical Works

• Re-elevate Proving unit for consistent piping elevations and ease of valve maintenance.
• Installation of new de-aerators, strainers and valves for dedicated product lines.
• Install new base plates, pumps and motors.
• Upgrade to tank nozzles from 2” to 6” to accommodate new lines.
• Complete piping fabrication and installation including structural works.
• Access to carry out work introducing new equipment to plant is done during shutdown periods in order not to affect operational requirements. The success is thorough planning, preparation and execution. Doing it right first time.

Moses Mabhida Stadium

• The manufacture of jigging gear for the assembly of the iconic roof arch.
• Support services for the roof structure project i.e site welding of roof supports and machining to components, modification to parts to site specific requirements.

KSIA 16” FUEL HYDRANT LINE REPAIRS OVERVIEW

Overview We pleased to have carried out repairs to defective welds on a 16” Fuel Hydrant Line in Durban.  We received a go ahead and started on site preparation on the 07th January 2010. This was based on 4 fabrication teams working day shift on welds repairs and denso wrapping. It was also instructed for us to have a night shift running from 14th Jan 2010 with 2 teams per shift.  By then we had mobilized to verify 300 weld repairs. The scope increased to verify all welds (+_1500 on a 8km 16” line) on site due to no tracebility. Due to new excavation and mechanical damage evident on pipelines it was required by AIA that MPI be carried out on all welds. Total labour compliment to excute the required task in the time frame at that stage was 300 workforce. Linear indications were picked up on some pipes and it was decided to change method of MPI moving forward, also coupons were removed and sent off for testing in laboratory.

Challenges

• Schedule, very very tight.
• Weather, no allowances for weather delays, cannot carry out the majority of site works during rain (R/T, MPI, Welding, Wrapping, H/T etc)
• Balance of indications to be uncovered (MPI), also additional work to replace lines with indications, approximately 24 sections at that stage.
• Water in the line, resulting in “repairs being necessary due to having to cut line and drain water so that a proper quality radiograph can be viewed.  Also the reshoot requirement has a significant delay as this is only evident after developing has been completed.
• Mechanical damage on pipe resulting in cut outs (now defined)
• Re-shooting due to debris / water etc in the line causing delays.

Mitigations

• Welding engineer involvement from Fabricon (Consultant) and AIA.
• Welding expert on site full time to view all repairs and take view on cut out vs repair.
• Afrox welding engineer also involved in trying new consumables (3 to date 309 and 9 chrome wire ).
• Template made on an RT so that AIA can use this as a visual aid to see depth due to visual acceptance criteria on code, not ability to see root on site.  Test piece ground to get the template in order to try and get test shot passing rate higher.
• Technical audit carried out as previously indicated  Conclusion
• The project was successfully and handed over on 01 May 2010.
• Fabricon order value R30 000 000.00

1.Petronet Crude Pump Stations – Motor Upgrades 2005.

The Scope of Work covered the removal, transportation, stripping and assessing, refurbishment, testing, de-rating, re-certification, delivery, installation, electrical cabling, cold and hot commissioning of Electrical Motors installed at Existing Pump Stations on the Crude Oil Pipeline.
The WORK was performed at of the ff. existing pump stations along the Crude Oil Transfer Pipeline System between Durban and Sasolburg:

• Fynnlands
• Hillcrest
• Howick
• Ladysmith
• Newcastle
• Quagga

Overview of Work Scope

• Removal of Existing Motors
• Refurbishment of motors where required
• Relocation of the motors to their respective future services
• Modifications to the existing pump set bases couplings and lube oil systems as required
• Installation and alignment of the relocated/refurbished motors
• Disconnection and removal of existing 3.3kV cabling.
• Supply and installation of cable racking.
• Installation and termination of the new earth cabling to relocated motors
• Modifications to the existing switchgear
• Setting, testing and certification of the 3.3kV electrical switchgear and protection relays and equipment.
• Disconnection, calibration, cold commissioning and hot commissioning of all equipment involved in the Work.
• Provision of all personnel, facilities and equipment as required.
• Project was carried out to the specifications and boundaries of the Scope of Work as required.

2. Petronet Duzi Pump Station – Fluor Daniel
Ref:   Mr. Morgan Naidoo – Tel – 031 460 3135
2003 – Main Crude Line- 12” schd.40 Piping mods and installation on shutdown. All welds 100% x-ray.

3. Petronet Pump Stations – Sulzer SA
Ref:  Mr.  Gavin Doran – Tel – 011 8206000
2002 to 2003 Pump driver upgrades on stations from Durban to Newcastle. Scope of work included manufacturing adaptor base plates, site installation of base plates, insitu machining for correct elevations installing new drives, laser alignment and commissioning.

4. Royal Swazi Distillers – Royal Swazi
Ref:  Mr. Stephen Mclean  – Tel – 914 3210
2002. Distillery relocation, Fabricon scope included stainless steel piping fabrication and installation.

5. Sappi Kraft – Sulzer SA
Ref:  Mr. Jonathan Fullford – Tel – 031 700 4821
2001 to date. Pump base plate manufacture and supply. Ongoing.

6. Sulzer SA – Engen and Sapref Refineries (Kwazulu Natal)
Ref:  Mr. Paul Barker – Tel – 082 781 4578
2001 to date. Rotating Equipment ongoing maintenance and laser alignment to all Rotating Equipment and cooling towers up to 5m DBSE

Petroleum Pump Station in Secunda – Mechanical and Civil Upgrade

• Upgrade to pump manifold, Manufacture and install new base plates, pumps and motors.
• Civil works for upgrade entailed design works, and construction of plinths for new pump set, and bund wall and floor areas.
• Complete piping fabrication and installation including structural works.
• Access to carry out work introducing new equipment to plant is done during shutdown periods in order not to affect operational requirements. The success is thorough planning, preparation and execution. Doing it right first time.