A recent audit of a “rebuild” design package for a major Asian gas plant identified that the EPC may have failed to follow company or industry standards. The owner needed an engineering review of the entire facilities’ relief systems designs prior to their start up in two months. Any deficiencies in company or industry standards needed to be addressed prior to the facilities’ start up.
Smith & Burgess quickly mobilized our staff to review the gas plant design. The review initially consisted of the EPC’s design packages; however, at the owner’s/operator’s direction, the project quickly morphed into a complete relief systems design package for the entire facility from scratch.
The Smith & Burgess engineering review identified major design deficiencies in the original engineering design scope. The main flare header was built using incorrect design specifications, and operation was identified as unsafe. The facilities’ depressuring logic was updated to incorporate recent discoveries from the offshore failures in West Africa. With the new relief systems design basis in hand, the customer had confidence the system was designed safely. Due to the diligent work of Smith & Burgess’ engineering team, the review was completed on time, within budget, and allowed the gas plant to begin operations as scheduled without any incidents.
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Gas Plant Detailed Relief System Design Review