Project Background
The J-46112 Compressor Turbine, along with its adjacent structures and roof sheeting, suffered significant damage in a fire incident at the Sasol 1 Monomers site. Urgent repairs were crucial for various elements, including the surrounding structure, crane plate girder, purlin beams, roof sheeting, gratings and handrails. Various Piping systems had to be sourced, fabricated and installed as part of the repair work. Classified as a priority one, these repairs demanded immediate attention as this was critical equipment that caused a forced shutdown of critical plants. Sasol entrusted the order to Megchem, who subcontracted New Age Engineering Solutions (NAES) based on our track record of successfully completing previous projects within the proposed schedule and budget.
Scope of Work:
- Initial Phase (end-November 2023):
- NAES received the initial order to number, tag, and remove damaged piping and plate girders.
- NAES Mechanical team disassembled damaged parts, and Megchem performed 3D scanning on the turbine piping and tubing.
Adaptation (Third Variation Order):
- NAES issued a third variation order to accommodate additional resources and materials needed to complete the project by the end of December 2023.
Challenges and Solutions:
- NAES navigated through unpredictable weather conditions, ensuring project momentum.
- Continuous creation and revision of piping isometric drawings: NAES exhibited agility, swiftly rerouting and adapting work processes to align with the revised drawings.
- NAES implemented a streamlined process for updating and revising piping isometric drawings, enabling quick and agile adaptations to the evolving project needs.
- The project’s scope dynamically expanded, calling for strategic planning and resource allocation.
- Breakdowns during December limiting available suppliers and service providers: NAES fabricated fittings due to limited suppliers.
Conclusion:
This project was concluded five days before the end schedule, and this was made possible by the well-established synergy between NAES, Megchem, SASOL, and other SASOL service providers, as well as the willingness to perform and can-do attitude of the NAES staff.
NAES received great feedback, letters of congratulations and gratitude from stakeholders.
