BP GF Gas Plant Asset Integrity and Refurbishment

Beta Scope

Our scope comprised the following:

Setting out a programme for the visual inspection, intrusive inspection, assessment, repair design, document submittal and execution.
Preparing “acceptance criteria” for client approval before carrying out any inspection.
Preparing the intrusive inspection scope.
The site inspection and the supervision of intrusive inspection.
Preparation of structural assessment report and repair design.
Supervising repairs on site.

The main activities in this programme were:

The assessment of the Steel Piperacks and their concrete foundations.
The assessment and repair design of the concrete sumps.
The assessment and repair design of the slug catcher foundations.
The assessment and repair design of the regen gas heater pedestal foundations.

Background

Beta Design Consultants acted as structural engineering consultant for Bechtel UK to carry out the structural inspection, structural assessment and repair design for the civil and structural facilities of BP Rosetta Gas Plant in Egypt (also known as Giza Fayoum Gas Plant). The plant presented unique challenges due to its location, maintenance history and client requirements. These challenges included:

Strict programme to agree, tender and execute the works during a shutdown period of 12 months.
Tight budget due to pre-forecast capital expenditure.
Plant location the Mediterranean coast, subject to a very corrosive coastal environment.
Typically harsh petrochemical conditions (oily and chemical contaminants) affecting civil and structural facilities.
The plant location in a seismic area (near Alexandria) meant all design had to consider seismic forces and seismic code requirements (ASCE 7-10 and AISC 341 Seismic Provisions).

The client’s future plan for the plant required the assessment and life extension of all civil and structural facilities to ensure they have a service life of 25 years.