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The goal of this Chemical Plant Reactor Systems Upgrade was to design and construct a new process area for a new product and a new tank farm to supply new feed to an existing reactor unit.
In one unit, H+M was tasked with emulating an existing process area, while expanding to accommodate new, additional raw materials. A combination of powders and solvents would be used to create a viscous material that would ultimately be extruded in a cleanroom environment to form a film, the finished product. In the other unit, H+M Industrial EPC was tasked to reconfigure existing reactors for the production of new materials. To accomplish this task, an entirely new tank farm was built to supply the new raw materials to the reactors. Pipe routing and supports were supplied throughout an existing reactor structure.
Design and construction in a cleanroom required special considerations. Significant fire and explosion hazard from a raw material present in the area and being rerouted to feed the new process; proper recognition and communication of hazards throughout the project resulted in zero incidents. Both units were in production during the time of construction. Coordination with Plant Operations to schedule breaks and reassign work areas around critical production tasks that required the area to be clear of personnel. Line testing required exclusion zones demanding communication and coordination with those onsite; in some instances, performed the task during off-hours or with short notice. Delivery timeline on several filters was extraordinarily long; H+M shop fabricated the housings eliminating an equipment delay impact.
The construction schedule was designed to allow for continuing operations at the facility. Clear communication with the client was key in making sure ongoing operations were not interfered with. The first project area was partially demolished to make room for a new foundation and pier work, a new structure required to support cable tray and piping, and a new mezzanine to support process equipment. New piping was installed for the new production area including tie-ins to existing lines. Special consideration was taken in the design of the jacketed pipe which had to be electro-polished and inspected by the client prior to installation. The second project area required site preparation for the installation of the new tank farm. Tie-ins to supply existing raw materials and utilities were made with piping runs throughout the unit. The materials were supplied to the existing reactors several stories high in the reactor structure requiring careful consideration for pipe routing and support. After construction was complete, our team supported the PSSRs.