REVIEW, VALIDATION, DUE DILIGENCE STUDY, OWNER’S ENGINEERING

Pipeline and Facilities Design & MDR Validation

  • Gas pipeline connection 4 km long having pipe size DN 750mm. Connecting metering station, pig launcher station and, receiving station. Valves. High temperature and pressure gas 10.2MPa at 79°C. The pipeline was having a upheaval force. Traditionally this would have been solved by less restraints or more restraints both of which would have caused issue to the design by causing unwanted stresses. Sustech’s solution made the project a success.

Stage 1 Expansion Facilities and Export Pipeline – Design & MDR Validation

  • Sustech performed the independent 3rd party review of design and construction MDRs. The Stage 1 Expansion Project will increase the capacity of a production facility to deliver up to 30TJ/d through a pipeline, enabling the Owner to continue producing from two existing wellheads, as well as allow other wells with a higher CO2 content to be tied-in to the plant. To enable this capacity increase, upgrades to existing equipment and installation of new infrastructure is required within the plant including a new gas export compressor package, upgrades to the existing Slugcatcher, existing Mercury Removal Unit (MRU), existing Fuel Gas system, existing Gas Conditioning system including installation of an additional new Gas-Gas Exchanger and a new LTS Separator. The validations were carried out in accordance with set terms of reference, pipeline and production licenses, WA acts and regulations.

Review of Water Distribution and Spray Systems

  • Sustech was engaged to review the report and calculations done by the owner’s other consultant and provide suggestions on the recommendations to solve the problems faced in the water distribution network. The system involved different pressure, flow requirements at different points. Material of construction was different. This is an important utility service for the mine. Sustech executed the role of owner’s engineer to the best interest of the client, analysed the system, identified the problems, found the causes, and directed towards the solution.

Custody Transfer Meter Station – Design and MDR Validation

  • Sustech performed the independent 3rd party MDR validation of the gas metering station. The goal of the verification was to complete an independent desktop review of the design and MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech has completed the validation satisfactorily within time and supported the project commissioning schedule. The client has decided to award the validation of another metering station and lateral that they will be building.

River Gas Pipeline- Pipeline and Facilities MDR Validation

  • Sustech performed the independent 3rd party verification of a 277 km natural gas pipeline lateral and its facilities’ Manufacturer’s Data Records (MDR). The facilities include Hot Tap, Metering Station, Pig Launcher- Receiver, Main Line Valve, Pressure Reduction, Heating and Custody Transfer. The goal of the validation was to perform an independent multi-disciplinary desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech completed diligent review, maintained detailed verification records, raised queries with constructor for clarification and closed queries to satisfaction. Sustech issued a report for the safety-integrity of the installation and a fit for purpose pipeline and facilities. The report was be submitted to the regulator.

Pipeline and Facilities Design & MDR Validation

  • Sustech executed the independent 3rd party design and MDR verification of a 440 km natural gas pipeline, its scrapper stations and metering stations at the head and lateral ends. The goal of the verification was to perform an independent desktop review of the design and MDR documents under the regulations of DPIR of the Northern Territory as per Energy Pipelines act 2015 and Energy Pipelines Regulations 2015. Sustech was engaged from the design review stage, attending HAZOP and Pipeline risk assessment workshops and keeping close contact with the operator and regulator and performing a diligent review, maintaining detailed verification records, raising queries with constructor for clarification, closing queries to satisfaction. Sustech issued a report for the safety-integrity of the design and a fit for purpose pipeline and facilities. The report was submitted to the NT regulator.

Seawater Supply and Desalination Plant Technical Due Diligence Study

  • Sustech did a technical due diligence study of an existing seawater supply system ~300MLD & desalination plant. This included sea water pumping, sea water pipeline 5 km over flood plain, high tide areas, storage, desalination, demineralised water storage, brine pipeline pumping, brine storage, ocean outfall of FRP pipeline. The study results were essential for taking investment decision and taking strategic policy decision. Sustech did a thorough job in assessing the technology, design, MDR, condition assessment reports, incident reports, failure reports, equipment fitness certificates, maintenance records, operational history, OPEX and CAPEX/ Project OPEX spent by operator. Sustech’s engineers visited site, assessed asset conditions analysed the records and submitted a conclusive report that was well received by the client.

FLNG Mechanical and Piping Design Basis and Scope of Work Review

  • As an independent reviewer, Sustech was entrusted to review the mechanical and piping section from the Basis of design for a 4 Mtpa floating LNG developed by another consultant of the owner. Sustech referred to the following documentation: owners’ requirements, key decision logs, site data, project philosophies, owner’s company guidelines to review the basis of design to identify the anomalies, deficiencies and advise functional sufficiency, safety points and improvement scopes to make the document as robust as possible to develop a proper FEED design. Sustech reviewed the scope of work on the basis of these documents to provide the FEED contractor with a clear understanding of the work.

Take Off Lateral and Meter Station – Design and MDR Validation

  • The Lateral is designed to transport gas from a gas plant to a Lithium Plant. The purpose of the design and MDR was to assess that the design was safe and fit for purpose and the construction records were evident of a complaint system installed and ready for safe commissioning and fit for the purpose of operation according to the licensing conditions laid out for the, offtake and metering facilities. The validation was done as per of AS2885 under the WA Pipelines and Petroleum Act 1969.

Gas Pipeline and Facilities MDR Validation

  • Sustech performed the independent 3rd party verification of a 100 km natural gas pipeline lateral and its facilities’ MDR. The goal of the verification was to complete an independent desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech has done a diligent review, maintained detailed verification records, raised queries with constructor for clarification, closed queries to satisfaction. Sustech issued the report for safety-integrity of the installation and a fit for purpose pipeline and facilities. The report was submitted to the regulator.

Gas Storage Facilities- Design & MDR Validation

  • Sustech was engaged to provide an independent 3rd party verification of design of the 42 PJ gas storage facility which is the largest in WA. The project involves multiple injection and recovery wells, wellhead filtration, flowlines, slug catcher, two stage two trains compressor station, gas processing facilities, dehydration, regeneration, hot oil system, mercury removal, metering stations, pipelines, pig launching and receiving facilities. The goal of the verification was to perform an independent desktop review of the design documents, that will ensure accordance with AS2885 and ASME B31.3 under the WA Petroleum Act 1969 and prodcution license. The project also involved the use of relifed mothballed vessels under AS3788 and API579. Sustech performed a diligent review, maintaining detailed verification records, raising and closing queries to satisfaction and noting obervations that may not affect the integrity of the project but could lead to uncontrolled hazards. Sustech issued a report for the safety-integrity of the design and MDR for a fit for purpose gas storage and processing facility. The report was submitted to the regulator.

Gas Development Project – Process Design Review

  • Sustech was appointed as the independent reviewer of the process design of the Sole Gas project. The process design and the technology selected was innovative and required highly skilled and experienced process engineers to look through the functionality, safety and fitness for purpose. Sustech reviewed all key process engineering deliverables like Process Flow Diagrams / Block flow diagrams / Heat & Mass Balance Diagrams / PIDs / Basis of Design data sheets / Performance guarantees / equipment selections / hydraulics / flare sizing / cause & effect charts / specifications / and data sheets. Sustech prepared the list of queries for the area of concerns; identified the risks associated with the process design; prepared the risk matrix (for the identified process risks) and provide suggestions to mitigate the risks; reviewed and confirmed the process guarantee parameters to meet the contract requirements. Sustech also highlighted if there were any issues in meeting the performance guarantees; identified the list of opportunities to improve the design to reduce both time and cost; prepared a consolidated report on the findings / remarks / recommendations / risks. Sustech’s engineering team with special expertise and a combined experience of over 100yrs completed the job and earned kudos from client.

Aviation Fuel Pipeline Review

  • Sustech reviewed calculations for pipeline crossing under railway and roads for client as per AS2885.

Gas Pipeline- Pipeline and Facilities Design Validation

  • Sustech performed the independent 3rd party verification of a 123 km natural gas pipeline lateral and its facilities’ MDR. The goal of the verification was to do an independent desktop review of the design documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech undertook a diligent review, whilst maintaining detailed verification records, raised queries with the constructor for clarification and closed queries to satisfaction. Sustech issued a report for safety-integrity of the design and a fit for purpose pipeline and facilities. The report was submitted to the regulator.

Consumer Gas Piping Regulatory Approval for Boiler, Reformer, Heater, Dual Fuel Flare

  • Sustech organised the compliance of Building and Energy Safety regulations the modifications and improvements of different type B gas appliances with the help of registered gas inspectors and Class I gas fitters. Sustech is adding value in doing the engineering of the modifications while liaising with the client and inspector to work for an acceptable solution for the regulatory body and improves plant safety, efficiency and reliability. This simultaneous and concurrent approach is the value addition of Sustech as an owner’s engineer.

Compressor Station and Metering Station-Facilities Design & MDR Validation

  • Sustech executed the independent 3rd party verification of a interconnect compressor station, metering station, pig launcher at the pipeline and facility transition for its design and MDR. The goal of the verification is to perform an independent desktop review of the design documents within the ambit of AS2885 under the WA Petroleum Act 1969. Sustech is performing a diligent review, maintaining detailed verification records, raising queries with the constructor for clarification and closing queries to satisfaction. Sustech is issuing a report for the safety-integrity of the design and a fitness for purpose for the facilities. The report will be submitted to the regulator.

PSV Sizing Calculation & High-Level Process Review

  • Client designed and manufactured a natural gas pressure reduction skid for facility. Client engaged Sustech to do a high-level process review and perform a sizing calculation for the PSV installed in a skid as per API and Australian Standards. Sustech reviewed the likely overpressure scenarios, identified relevant process parameters and performed process calculations to accurately determine the adequacy of the PSV’s selected for each gas and water system of the shell and tube heat exchanger designed to AS1210. The work was completed with little notice and within a small timeframe, as the skid was already at site. The customer took Sustech findings on board and incorporated the calculation and review records.

Interconnector Design Validation

  • A Interconnector pipeline, 3.3 km-long buried steel natural gas pipeline in Western Australia is being built. The Project will enable the transport of raw gas from an LNG Plant to to a processing Plantrocessing. The gas plant is operated by the contractor on behalf of the client. The LNG Plant was commissioned in 2006. The pipeline is licensed under the Petroleum Pipelines Act 1969, under PL122. Sustech is performing the third party design validation of the interconnector project.

Metering Station- Upgrade and Interconnecting Gas Pipeline MDR Validation

  • Sustech performed the independent 3rd party MDR verification of the existing gas metering station upgrade and the interconnecting natural gas pipeline. The goal of the verification was to complete an independent desktop review of the MDR documents within the ambit of AS2885 under the WA Petroleum Act 1969.

Consumer Gas Piping & Reformer Burner Efficiency Enhancement Regulatory Approval

  • Client was replacing the existing burners for enhancing the thermal efficiency of the reformer. Sustech was engaged to assess the extent of changes of the burners being replaced in light of the gas act 1972 and engage qualified gas inspectors and gas fitters and co-ordinate with Energy Safety via gas inspector and obtain the approval for operation of the reformer. Also, Sustech engaged Energy Safety certified gas fitter for supervising all gas fitting work in the consumer piping witnessing leak tests and working closely with client commissioning team, gas fitter and gas inspector to ensure a safe and regulator approved gas piping system inside plant.

Hydrogen Network Costing Estimation for 10% and 100% Hydrogen blends

  • Enlisted by client to further iterate on an early cost estimation for the introduction of Hydrogen into an aging network. This costing estimation provided a high-level breakdown for Hydrogen introduction into the system which involved the research into the asset as well as the differing components that would be directly involved in Hydrogen introduction and the potential effects of this.

    During the project Sustech conducted basic preliminary engineering assessment of assets of natural gas distribution network to review the compatibility for 10% Hydrogen blends and 100% Hydrogen for the existing network and modifications needed for 10% Hydrogen blends and 100% Hydrogen for the existing network. Cost Estimation for modifying/ upgrading the gas network for 10% H2 and 100% H2 compatibility and addition of localised hydrogen generation stations at city gates.

Fuel Transfer to Wharf Bunker Line – island Pipeline Design

  • Sustech was engaged by a client who specialises in fabrication and installation to do the design for an island’s fuel refilling bunkering line from the tank farm to the existing wharf. Sustech did the mechanical design and the civil design for penetrating the jetty slab and checking the structural integrity for the slab with the disturbed reinforcements and designing remediation solutions for the slab. The whole design work was done through remote data collection and design feasibility verification by the client’s site manager. Sustech did a similar job for another company for their line in the same jetty.

H2SO4 piping - Stress Analysis and Detail Design of Brownfield Modification

  • The client engaged Sustech Engineering to visit and site and perform a survey for the brownfield modification of the piping of the H2SO4 system. On a successful assessment and budgeting provided to the client, contractor was awarded the job and Sustech was in turn engaged to complete the piping design and pipe stress analysis and support design for the modification package for cooling tower dosing, storage, mixed bed exchangers etc. Sustech developed the design keeping the shutdown planning in mind to allow maximum prefabrication and minimum site work during the shutdown periods. Pipe stress analysis was performed in Caesar II for all possible scenarios and drawings were produced to the fabrication level.

Waste Water Discharge System Engineering and Design

  • Sustech Engineering has been retained by the client for engineering and designing a new wastewater line from the existing sewage treatment plant to a brine line discharge. This complete engineering package involves pump sizing, pipe sizing, system process design, mechanical-piping detail design, electrical design as per available infrastructure, layout and route selection, making MTO, supporting procurement and construction. This is a fast-track project for environmental compliance. Sustech is engaging senior professionals of the team for the timely and fit for purpose execution.

Nitrogen bypass line – Project Management Piping Engineering

  • Sustech was engaged as the project manager and mechanical-piping consultant for this brownfield modification project in the existing LNG plant as a sub-consultant. A bypass for the Nitrogen system was designed in a level of detail that the client could procure and install. After a site visit for both information and data collection, all the necessary calculations were done, datasheet were produced; isometric and instrumentation drawings and documents were produced – ready to use for installation; design, constructability and safety reviews were conducted. The project was delivered within the allocated timeframe, to fit into the shutdown schedule of the plant.

Wellhead Manifold -Skid-Offshore- Structural Design- Analysis and Fabrication Drawings

  • Sustech’s structural engineer and designer performed the calculations and drawings for the wellhead platforms, manifold skid, console frame within a fast turnaround period, beyond regular working hours. The criticality of the project was achieved through a conforming arrangement with the piping engineer, a design based on the availability of materials, with close co-ordination with the fabrication team under an activity in the highly critical path of the schedule.

Pontoon Dry Dock FRP Piping Analysis and Detail Design of Brownfield Modification

  • Awarded to replace valves in the seawater suction and discharge FRP piping system inside pontoon floating decks. This needed using special couplings to join the FRP pipes and some butt and wrap joints. Sustech was engaged by the client to do the engineering drawings and pipe stress analysis and supports design and deliver the detail brownfield engineering. We visited the floating dock, entered the confined space, took pictures and dimensions and checked support feasibility inside the pontoon. We shall also look at the naval structure of the floating deck as relevant and deliver the design.

Seawater-closed-circuit Freshwater cooling GRE Pipe Refurbishment

  • Sustech was entrusted with the owner’s engineering role for developing the scope of work for detail engineering consultant, technical bid evaluation of manufacturer and installation contractor, managing/co-ordinating the total project, reviewing the design of the seawater cooling and freshwater cooling system of the client, providing D6 qualified inspectors. Glass Reinforced Epoxy (GRE) was chosen as the piping material with some pipes of GRVE. A flow analysis, stress analysis, construction feasibility was assessed for the new proposed piping system. Sustech was working on behalf of the owner to achieve a design that was safe, functional, code compliant and constructible and manage the project for the largest running Ammonia plant in Australia, whilst being commissionable within a very short turnaround time. Sustech helped the client to develop a scope of work for both supply and construction. A very carefully thought-out piping replacement and refurbishment procedure with minimum or no disruption to operation was the challenge. The empathetic understanding and efficient managing of the agencies from multi-country and directing to the common goal was the key to success. Project was completed ahead of time and commissioned successfully.

Fire Water Piping - Brownfield Modification to Hydrants & Pump Skids Interconnect

  • Client extended its fire water network from existing hydrants to compressor stations and the related pump skids. The design, engineering, supply and installation of the fire water line with its accessories from the existing hydrants to the compressors was awarded to the contractor. Sustech developed the piping, pipe support, structural and civil design and engineering including the pump foundation design from startup for this brownfield modification. Sustech attended site visits, conducted surveys to understand the client’s requirements and preferences. The Sustech team is experienced and performed all stress analysis, structural analysis, foundation analysis and design for a fit for purpose design.

Domestic Fuel Supply Project – FRP Fire Water Piping Engineering & Pipe Stress Analysis

  • Sustech was engaged by the contractor to design and perform stress analysis for the fire water system involving the buried FRP piping for the fire water mains, installed for the client’s domestic gas supply project. Sustech is a niche player in the field of FRP piping engineering and pipe stress analysis with knowledge of NOV pipes and piping components as well as other manufacturers. FRP piping design and pipe stress analysis is very much a vendor entwined engineering process and Sustech has done that for the contractor numerous times and delivered the job correctly within the timeframe.

DESIGN, ENGINEERING, ENGINEERING MANAGEMENT, PROJECT MANAGEMENT

Lean/Semi-lean Heat Exchanger – Troubleshooting and Brownfield Modification Design

  • The client had a lean/semi-lean exchanger installed with a new plate pack. The exchanger had start up troubles and resulted in an extended downtime period whilst the plate pack had to be cleaned. Sustech is providing a solution is required to arrange for installing a new plate heat exchanger (as a redundancy unit); either at the level below current location, or at ground level. In order to do this, a complete engineering design must be completed with all required piping modifications to ensure that there will be a standby unit. Based on the process, a feasible solution must be provided with all required supporting documentation for the proposed design. As stated previously, the new exchanger location must be proposed for both, compatibility of service, as well as maintainability of the exchanger.

Ship loader MCC room Transportable Structure – Structural design analysis and calculation for transportable MCC room

  • Sustech designed the transportable MCC room that was installed at Geraldton port, on the Ship loader located at Berth 4 as a subconsultant. Sustech analysed the building and included all major structural members and light sections using STAAD Pro. This included all types of probable loads, including transportation loads, wind loads, ship loader movement loads, and equipment loads. Calculations were performed as per Australian Standards to satisfy all regulatory requirements. The serviceability of the equipment was considered while selecting members. All connection details were calculated and provided for shop fabrication.

GRE Pipe Stress Analysis Piping Engineering of Sea Water Desalination System

  • For this project, Sustech contributed to the modifications of the existing system to suit the tying in needs with a new installation as a sub-consultant. Sustech performed the pipe stress analysis of the existing GRE piping system and the modification work in CAESAR II and used inhouse software to ensure the installation was compliant with ISO 146920, in adherence with AS1170.2 and 1170.4 requirements. Sustech suggested changes to the existing piping support system to suit the proposed modification. Sustech designed an additional support for the modification as well as providing the footing design. Sustech also prepared fabrication isometric drawings with MTO.

Lube Storage – Pipe Stress Analysis in Caesar II of Engine Oil System

  • Sustech performed the pipe stress analysis of an engine oil system in CAESAR II together with tank, pump, supply end connections as a sub-consultant for client. Sustech helped selecting supports and suggesting changes to special supports. All load cases were considered including wind and earthquake as per AS1170.2 and 1170.4 requirements. The analysis was performed in accordance with ASME B31.3.

Perth- Workshop retaining wall - Detail design of brownfield modification

  • The client modified its workshop to optimise its space usage. Sustech designed a retaining wall to claim level space that can be used for workshop related work. The design was developed based on client requirements and considered soil pressure and all other relevant forces. The design was backed up by proper Space Gass calculations certified by a Chartered Engineer that was submitted to the local council.

Drilling Fluid Transfer to Wharf– Project Management & Pipeline Design

  • Sustech was engaged as the project manager and the mechanical piping/pipeline consultant for this project in the form of a sub-consultant. The project involved a site visit for routing a pipeline and was a communication intensive project which Sustech handled skilfully. The fluids handled varied from slurry to hydrocarbons that involved adherence to different codes and standards. The range of materials considered for construction varied from carbon steel to duplex to GRE. All engineering disciplines were involved due to the variety of skills needed. The design team had people from Brisbane, Sydney and Perth. The engineering was done from scratch, as was the pipeline route selection. The route went under the wharf and was a combined land and marine pipeline. Accurate determination of Pipeline pressure was the most challenging aspect of the project, as different vessels came with different pumping capabilities. The pipeline route had an interface with other facility owners and other projects on the barge. This was a project full of challenges and Sustech overcame these and executed the project to the client’s satisfaction.

Specialised Welding Australia Boiler Attemperator Design

  • Sustech Engineering was engaged to design the boiler attemperator vessel including the shell (waterside); and the steam side tube bundles, tube sheet, steam header box; all nozzles as per AS1228; and internal and external supporting arrangements. Sustech has done the design with in-house spreadsheets, checked special components subjected to differential external pressure by FEA, got the design third party verified and helped in the registration of the vessel with Work safe.

Wastewater Discharge FRP Piping - Detail Design of Brownfield Modification

  • The client put in a new wastewater discharge line of RTRP material in their existing plant tied with its existing process. The contractor was engaged to design, build and install the plant with its equipment, piping and accessories. The piping material used was FRP Ameron Bondstrand 2400 series. Sustech developed the piping and civil design and engineering from project beginning for this brownfield modification by attending site visits, surveying, and understanding client’s requirements and preferences and designing in accordance with ISO 14692, and AS codes. Sustech placed suitably skilled and experienced engineers and designers to perform the right engineering by Caesar II, STAAD PRO, SPACEGASS calculations and make the project a success.

Double Walled Portable Tank Design

  • Sustech has developed a proprietary double walled self-containing tank design for diesel storage as per AS1692 and UL142. The design has been developed and all engineering calculations done to satisfy the Australian codes and regulatory requirements. This is a portable type of tank suitable for mine sites or camp sites. This is a modular design scalable to required storage volume requirements. The ergonomics, safety, operability fabrication cost savings, transportability has been optimised in the design.

ELECTRICAL ENGINEERING

Electrical Grid Design Review & Remediation​

  • A client’s ammonia plant has an islanded electrical grid that was experiencing issues that would cause frequent blackout events, disrupting the operation of the plant. The sister plant was also affected as it draws power from the main plant, thus a blackout would interrupt operations for both plants. The client engaged Sustech to provide an assessment of the grid to ascertain the main issues and provide high level recommendations to improve reliability. During the lengthy study, Sustech diligently reviewed all the related documentation on incidents, design, and operating philosophy as well as conducted site surveys to collect information from the client’s onsite engineers. Sustech also carried out power studies through DlgSILENT Power Factory. At the end of the assessment, Sustech issued a detailed report of the findings as well as an obsolescence study, in which the recommendations for improvements were further detailed.

Concentrate Dryer Lighting & Earthing Design

  • An earthing mesh was already installed under a concentrate dryer structure, making it hard to connect the earthing system with the mesh and structures in the way. Sustech was engaged by the client to design a new earthing system connecting steel columns at no less than two points. Sustech reviewed the client's engineering calculations, risk assessment and prepared drawings accordingly.

Electrical Pre-Feasibility Work for Addition of Solar Power station to Mine​

  • To address emission concerns, client intended to install a solar farm at an adjacent area offsite to the existing mining operation.​ In conjunction with this, they planned to expand the plant (4MW-12MW) by modifying the current layout, which would eventually block straight line access to the solar farm from the mine.​ Sustech was engaged to provide a preliminary concept and notional costing for the cable routing from the mine site to the solar farm, including different scenarios (above ground indirect, underground direct, different cables etc.)​

Electrical Verification of Tie-in Design for Environmental Remediation

  • A client, as part of works related to delivering environmental remediation solutions to their plant, required verification of a planned power tie-in design. This verification included circuit breakers, distribution boards, and routing into and out of the equipment room. Design documents were updated in line with the client’s quality standards and requirements. Once completed and approved, the documents were delivered to site personnel for construction.

Electrical Drawings – As Built Modification of Electrical Drawings

  • Sustech updated the “As Built” marked ups in the final version of the Electrical single line diagrams, cable schedules and layouts. Sustech used its low cost overseas centre for its main drafting work with some application of design, engineering, and site knowledge. Sustech was given little notice with a fast-approaching project deadline. Communication was the key factor which Sustech successfully established and exercised, to ensure a smooth and timely delivery.

Structural Integrity - Engineering Support for Structural Integrity Remedial Work

  • The client had performed a preliminary integrity assessment of their aging plant structures and provided a package to the contractor to execute the suitable modification and integrity work. Sustech was engaged by the contractor to do detail integrity assessment of individual members, perform necessary calculations and develop the work method statements for each work pack. Sustech analysed the structures, inspecting and assessing the condition and suggesting the work for the field crew.

Synthesis Gas Piping Stress Analysis and Support Spring Replacement

  • The synthesis gas piping from gas heater to the ammonia converter had issues of non-functioning spring, cumbersome operating procedure of shimming rest supports at the start up, and high loads at equipment nozzles. Sustech was engaged by the client to address the issues and suggest new springs. Sustech stress analysed the line suggested modified supporting arrangements and new springs to reduce loads at nozzles and get rid of shimming at the rest supports.

Iron ore mine Site-Condition Monitoring

  • Sustech provided data collection and analysis support for the client’s site on subcontract for stationary rotating equipment condition monitoring. Sustech performed vibrational analysis, reviewed oil reports, raised maintenance notifications, performed weld thickness testing and maintenance. The prompt capable support was appreciated by the client.

Steam Turbine Shaft Misalignment Solution

  • During regular operation, the back-pressure steam turbine was tripping occasionally due to shaft misalignment. Further observations revealed that the turbine exhaust nozzle flange was having uplift and parallelity issues. The root cause was assessed to be the turbine exhaust steam piping configuration. The piping during the operating condition was pushing the exhaust nozzle up and tilting it, thus creating the turbine shaft misalignment. We did the pipe stress analysis of the line to simulate the situation and understand the problem. The layout was stiff and not qualifying the NEMA SM23 allowable loads at the exhaust nozzle. We provided a total solution within line pressure balance expansion bellows to qualify the loads. But as the start-up of the turbine was due in short time, so we had to come up with an in-service solution which could be implemented while in operation. We changed springs and modified supporting arrangements to provide for solutions to stop turbine flange lifting and tilting and stopped it from tripping.

Pipe Stress and Finite Element Analysis of Propane Kettles Trunnion Temporary Supports

  • Sustech was engaged for pipe support FEA and Pipe Stress Analysis of Propane Kettle connected DN500 and DN400 lines of the client’s LNG plant. Sustech performed stress analysis using Caesar II considering increased slug loadings & heavy loadings of higher sized valves. Due to limitation of welding a temporary solution was planned till next shutdown. A temporary support next to the existing trunnion was provided to distribute the loads. The temporary support suggested was a special clamped shoe taking the vertical load and the existing trunnion will be taking care of the axial load. In order to confirm the integrity of the suggested support arrangement, FEA was performed using NozzlePRO on the Trunnion that had to withstand heavy axial load and special clamped support which is subjected to vertical and guide loads for Normal, Maximum Design and Upset Temperature conditions. The suggested design was meeting the codes and standards.

Ammonia Plant-Condition Monitoring

  • Sustech is providing support to the client for data collection and analysing of stationary rotating equipment for the client’s condition monitoring programme. Sustech aims to continue to improve the accuracy of remaining life prediction through improved awareness of the machine dynamics. The proficient experienced service is acknowledged by the client.

CO2 Flash Drum 60m Tall - Tower Vibration Remediation

  • Client has a MDEA CO2 removal system. The piping between the high and low pressure flash drum (60m tall tower) sees two-phase unsteady flow patterns, thereby causing vibrations and oscillations of the piping and mechanical structure. This flow is determined to be in the slug regime. High vibration was observed on AMDEA LP flash line. The high vibrations have resulted in damages of the components in the past. Sustech was engaged to analyse the problem and suggest the solutions. Based on the vibration measurements, process inputs, vessel and piping configuration with all its supports and components, Sustech performed static and modal pipe stress analysis in Caesar II. We weighed our options for the solutions implementable in the running conditions. We did FEA in Ansys for all the support components, members, vessels clits and repads to check the vulnerability points. We checked the natural frequency against the induced frequency. To strengthen up the piping system we suggested added support types on existing structural members. We prioritised the implementation. Our solution worked as the vibration is now reduced 9 folds even with minimum implementation of our recommendations. We are satisfied that we attained higher safety for plant operations.

Fired Heater Tubes Fitness for Service Assessment - Mechanical analysis & advise

  • The client was on a shutdown and had concerns about starting up a fired heater because the wall thickness of the tubes had significant metal loss. Sustech did API579 Fitness for service assessment calculations and API 530 calculations and looked at other NDT test results to advise the client for a safe start up but under a constant monitoring regime of fitness for service. This enabled the client to come out of the shutdown without major delay and loss of production.

Troubleshooting and Safety Compliance consultancy

  • Sustech has been involved with another consultancy company specialising in waste. Sustech has helped the client to engineer a safe optimised process to operate the plant in a fit for purpose manner. Sustech has reviewed the existing process and attain process safety through studies like and risk assessment studies and new modification designs. Sustech has done all the mechanical, EC&I designs needed to comply to the Australian standards and regulations. Sustech has helped change the PLC programming to accommodate the modified process and its operations sequence, shutdowns and automated responses. Sustech has procured the equipment and managed the installation. We have written the operations and maintenance procedures with the changed process.

ASSET INTEGRITY, PROCESS SAFETY, TROUBLESHOOTING, FITNESS FOR SERVICE, CONDITION MONITORING

Ammonia Reformer Steam Coil, Hot Process Air Coil and Piping Life Extension Solutions

  • During a regular planned shutdown the client noticed distortions in the steam coils and displacement of coil headers. At high temperatures and pressures the coils were subjected to creep and fatigue. Metallurgical and NDT inspections done by the client showed the remaining life of steam coils have reduced than original design life but still good to go for some years. Sustech was engaged by the client to find the reason of the damage and suggest means of improvement to slow down the reduction. We did a site visit with the client’s maintenance engineer to do the initial visual assessment of the coil and header condition. We understood that the internal coil design of the reformer is not being able to withstand the piping loads from the reformer external piping. We did pipe stress analysis of the coil connected steam piping to find solutions to ease the loads on the coil header. The high stress levels and distortions in the coils were reducing the remaining life. The solution was restricted to no piping layout change as that would delay the start up and result in huge loss of production and revenue. So, we focussed on the support modifications and releasing loads on the steam header. We designed new supports and selected new springs modified existing supports and provided solutions to stop accelerated remaining life reduction of the steam coils and headers. We did similar exercise for Hot process air in the same ammonia reformer. Lines are connected to secondary reformers also.

Cooling Water Circuit Hydraulic Analysis and Debottlenecking

  • Sustech is carrying out hydraulics study of Closed Cooling Water System (CCWS) for the client to ascertain bottlenecks if any. The Closed Cooling Water System (CCW) for the clients’ facilities consists of a closed water circulating system, cooled by plate heat exchangers with sea water from Cooling Tower. The closed-circuit demineralised water circulates in Nitric acid, Ammonium Nitrate plant to take away the process heat from the system. The outcome of the hydraulic study is to develop a hydraulic model for different operating conditions, calculate the flow rates and pressure drop across major equipment and increase cooling efficiency.

HAZOP Facilitation

  • The goal for this project was to reduce the loss of energy by blowing off steam. Sustech was engaged as the facilitator of the HAZOP workshop for this design. Sustech organised and ran the workshop involving the client’s process engineer, the operations and maintenance representative, the designer of the project, the project manager and the safety representative. All probable hazards and operability issues were discussed and captured in the company format. A HAZOP report was issued.

FEA and Pipe Stress Analysis of Equipment Nozzle

  • Sustech had initially been asked to conduct an FEA analysis on a Nozzle for a 125 MD pressure vessel. The assessment was to conclude if the flange design was adequate as per loads provided from the drawings from client. The assessment had shown the loads would cause failure and as such Sustech had provided recommendations to correct this. The provided stressed however from observation had been conservative and Sustech recommended client to conduct a pipe stress analysis to determine the actual loads, which Sustech had been contracted to do which showed the results to be within ASME B31.3 allowable limits, being rechecked in FEM to show them as suitable without modification.

Cooling Tower FRP Pipe Header and Structure Damage Remediation, Plant Cooling Capacity Increase

  • While on operation an incident happened to the cooling tower. A portion of the sea cooling water header came down and damaged the louvers and structures in its way. Sustech was engaged by the client to contribute to RCA and be the owners engineer in guiding and overlooking the technical and design side of things suggested by the cooling tower FRP structural contractors and FRP piping vendor and installer. Sustech also provided project co-ordination support. Sustech worked closely with the client’s operations, maintenance, reliability and project team to turn around the plant back to production within a very short period of time. More to it – Sustech analysed the flow distribution of the sea cooling water header and branches to the CT cells to address long standing low performance and efficiency of cooling of the plant. Due to Sustech’s process engineering analysis work the client’s plant has now an increased capacity of cooling. This means millions of dollars savings just in few months.

Converter Rail-Anchor Bolt and Concrete Assessment

  • Anchor bolts used to fix the rails on which the ammonia syngas converter head runs were corroded. New replacement bolt holes were drilled by maintenance contractor in the concrete. Sustech assessed and analysed the damage that happened on the reinforcement of the concrete and advised future course of action.

GRE pipe Incident Root Cause Analysis

  • Sustech was part of the expert team engaged in the initial root cause analysis study of the incident in the cooling water system as a sub-consultant. The pipes were constructed of GRE material with a buried and above ground combined installation. Sustech contributed to paving the way for a detailed pipe stress analysis, utility process and GRE material study and writing of the report identifying the root cause.

Hydraulic Cylinder Mounting Bolt troubleshooting

  • In this project Sustech dealt with a problem of a hydraulic cylinder mounting bolt. Sustech collected information from the client about the problem, defined the problem, reviewed all the reports suggested by its consultants. Sustech performed recalculations from the collected data and provided a viable solution. It worked, and the client saved a lot of money in terms of lost time.

Underground FRP Fire water Main Analysis and Assessment

  • Sustech was entrusted to find out the reason of failure of underground large diameter fire water mains and suggest remedial action. The running plant solution was needed fast to minimise the downtime. Sustech collected the information about the existing installation and the failure history. Contacted vendors for proper MDR inputs. Simulated the conditions through pipe stress analysis. Worked out the right fittings parameters and soil conditions and supporting arrangement needed. The report with site instructions and methodology was provided for the contractor. The piping system is running right with the remedies executed. Sustech feels a sense of achievement by solving these odd problems and helping the client.

ROOT CAUSE ANALYSIS, FORENSIC ENGINEERING AND RETROFITTING ENGINEERING

Assessing Design and Construction of Structure and Engineer Retrofitting Design

  • Sustech was entrusted to find out the suitability of the industrial structure in a cyclonic region. This was an emergency job. Sustech immediately flew to site and assessed every aspect of the buildings from a strength point of view. Sustech provided the client with an immediate action plan to keep the structure safe in case of a cyclone. Sustech performed the engineering to make the building fit for purpose. This involved several retrofitting works at site. The engineering and design needed careful attention to ensure the existing functionalities and integrity are kept intact. Checks were done to maintain that no new risks are brought into installation.

Diesel Tank-Structural Risk Review, Analysis & Temporary Structure Verification

  • The client engaged Sustech to perform a maintenance job for a API12B tank. Sustech as a sub-consultant, analysed the tank structurally from both a serviceability aspect and from an ultimate limit state angle, to determine the stability of the tank without the central pole. Sustech calculated and advised on the requirement for further temporary supports for tank roof stability.

Sheared Air Line Clamp

  • Sustech was engaged by the client for designing and analysing a clamping system for a broken sheared pressurised airline elbow joint. Sustech analysed the clamping arrangement through FEA taking care of the all the failure modes and putting together the line to functioning state. The clamping system was fit for purpose and tailor made to help the client perform live installation safely. We got appreciation for innovative solution and prompt action in this operation-maintenance work in resuming full service of the running plant.

Diesel Tank Construction Temporary Structure Analysis

  • The client wanted conduct a maintenance job in an API12B tank. Sustech was engaged as a sub-consultant, analysed the tank structurally from serviceability aspect and also from an ultimate limit state angle to find out the stability of the tank without the central pole. Sustech calculated and advised on the requirements for further temporary supports for the tank roof stability.

Sea water FRP pipe support design - Detail Design of Brownfield Remedial Modification

  • Sustech was engaged by the contractor to suggest and design a support for the large diameter sea water line. The pipe material was GRE. Sustech collected the information regarding the broader picture, assessed operating modes and conditions, suggested client the way forward and designed and engineered the special support for the retrofitted design to client’s requirement. An engineering analysis was performed for the pipe support with all possible load combinations. Detail shop drawing was developed for the ease of fabrication.

Propane Kettle Piping Stress Analysis and Support FEA

  • Sustech Engineering has been engaged by the client for performing pipe stress analysis in Caesar II of Propane Kettle Piping after splitting support types from single location to two adjacent locations and confirm the integrity of the system and local stresses by FEA by Nozzle Pro. The goal of this exercise to provide a safe solution without hot work on the pipe to avoid any shutdown. This is a fast-track project in the critical path of plant operations and maintenance. Sustech is engaging senior professionals of the team for the timely and fit for purpose execution.

Steam Line Clamp

  • Sustech was engaged by the client for designing and analysing a clamping system for a cracked drain pot line, which was at the verge of leaking. Sustech analysed the clamping arrangement through FEA to stop any leak and stress analysed the steam line to suggest new supporting system to stop further future deterioration of the steam line. The clamping system was out of the ordinary and tailor made to help the client perform live installation safely. We took pride in our prompt action in the matter for this running plant.

Lifting ring-lug design solution and FEA

  • Sustech was engaged by the client to provide design engineering solution and for lifting an installed pressure vessel and analysing the arrangement of lifting ring and lug to ensure integrity and safety during the lift. Sustech assessed the vessel and discussed the lifting methodology with the client and came up with a fit for purpose solution to suit the lifting crew, designed and engineered the special arrangement. An FEA engineering analysis was performed for the lifting ring-lug considering all possible failure modes.

OPERATION AND MAINTENANCE SUPPORT ENGINEERING

Design of temporary structures for Gas Turbine rotor pull out Maintenance

  • Sustech was entrusted to design and check the safety and integrity and functionality of the modification performed in the temporary structure used for pulling and resting GTG rotors for maintenance. Sustech immediately flew to site and executed the job in record low time. Sustech co-ordinated with the site team round the clock to ensure that the suggested changes happen before the shutdown. Sustech issued the design and was signed off by our CP Engineer. It is our aim to deliver efficiently to clients in their time of need. The client appreciated our efforts and rewarded us with a recommendation letter.

Steam Line Flange Clamp

  • Sustech was engaged by the client for designing and analysing a clamping system for a leaking steam flange. Sustech analysed the clamping arrangement through FEA to stop any further leakage, taking care of the all the failure modes and avoid further future deterioration of the steam line. The clamping system was out of the ordinary and tailor made to help the client perform live installation safely. We took pride in our prompt action in this asset integrity design engineering work for this running plant.

Maintenance solution with custom made pipe clamp - Design and FEA

  • Sustech was engaged by the client to provide design engineering solution for containing a pipe. The conveyed fluid was hazardous, so hot work had to be avoided. Sustech worked with the Taylor team to work out an on-field solution that can be employed online. Sustech’s experienced engineers assessed pipe, its operating conditions, materials, fluid, configuration and came up with a fit for purpose custom-made clamp solution, designed and engineered the special clamp. An FEA analysis was performed for the clamps defining the imposing loads to check the integrity. Detail shop drawing was developed for the ease of fabrication.

FRP & HDPE Sea Water Lines - Detail design of brownfield modification

  • The client planned to put a chlorination plant in a suitable spot in its existing plant for water treatment purposes tied with its existing process. The contractor was asked to design, build and install the plant with its equipment, piping and accessories. The piping material is FRP and HDPE carrying sea water. Sustech developed the plant and piping design from startup for this brownfield modification by attending site visits and understanding client’s requirements and preferences. Sustech put experienced personnel and appropriate resources to make it a success.

Work on mine - Pipeline pre-feasibility design costing  

  • Sustech reviewed and updated the possible pipeline route for a 320 km slurry pipeline to provide comparative data on the means of transporting iron concentrated from near Broken Hill to a site on Spencer’s Gulf in South Australia. The route, piping, pumping system and associated facilities was costed to a ±30% order of cost estimate to determine the feasibility of this option vs other methods of transport of the iron concentrates.

Gas storage coalescing filter 

  • As part of continued support often Sustech is contacted and hired to solve issues that may arise over time in projects. A gas storage facilities coalescing filter was not dropping out enough condensate. Sustech reviewed and modelled the coalescer. Used process simulation and suggested means to get maximum output before coalescing filter be installed.

Rubber-lined pipe- Fabrication detail drawing

  • The client was given the fabrication order for rubber lined pipes for mining operations requirement. Sustech used its experience and knowledge of rubber lined piping in both the water industry and mining industry to produce the drawings in a fast turnaround period.

Culvert Sampler Concept and underground water treatment validation  

  • A system was built to move underground water containing ammonia nitrate and other chemicals in amounts higher than regulation through an underground culvert which would sample the water quality. This water would then be treated and repumped underground. This sampling was important in ensuring that the water treatment was working as intended as well as to rectify the ecological impact of the contaminants. The data collected was handled and reported via a SCADA. To complete this project Sustech was required to draw upon our expertise of; specialised and sensitive water quality instruments for monitoring, solar/battery power to ensure continuous operation and a strong civil and structure foundation to build a control hut to house the sensitive instrumentation. This project was done successfully as to comply with state regulations. This project was done to in relation to a hydrogen project which required treated water to create the renewable hydrogen gas.

Gas storage oil separator

  • Oily water in a gas plant was collected in a tank that was meant to separate the two. This tank was not functioning as intended and as such the client had to frequently evacuate the full contents of the tank as the water could not be dumped into the evaporation pond. Sustech reviewed the installation and the process and suggested measures to make it functional to the extent of the existing design. Sustech suggested a correctly designed separator to avoid expensive OPEX.

Hydrogen project

  • For this project Sustech was brought on to select materials fit for distribution of Hydrogen. As such Sustech created a piping spec and made selections for both piping and valves. The Hydrogen project was built to produce renewable hydrogen that could be used to create power for the local network as well as reducing that communities carbon footprint. This project being community based required Sustech to provide technical coordination with the city’s council. This project aligns with Sustech’s goal of a sustainable future as it aimed to assist in an ever-growing renewable’s network.

DESIGN DRAFTING WORK

FRP Flooring and Walling – Structural Design-Drafting

  • Sustech participated in a joint site survey with the owner and defined the scope of work for the brownfield modification work as a sub-consultant. Sustech ran a design selection session for the optimum path for fabrication and performed necessary structural calculations. Sustech developed a 3D model of the FRP flooring and wall of different levels of the flash tank adjacent structure. Sustech got client agreement and developed detailed fabrication drawings and MTO for shopfloor fabrication and installation by the contractor.

Piping relocation design

  • A project required a pipe to be rerouted above ground, this rerouting created immense force and moments on the compressor and the foundation. Sustech discovered this through analysis and worked to remedy this issue through modification of pipe support as well as additional pipe support types and foundation modification design.

Underground and Aboveground All Services GRE, GRVE Pipe Assessment, Remediation Design, Refurbishment, Replacement Project Management

Unit cluster development and building

Underground nitrate mitigation environmental project applying new technology and satisfying regulatory compliance

Underground and Aboveground Sea Cooling Water Service GRE, GRVE Pipe Assessment, Remediation Design, Refurbishment, Replacement Project Management

Nursing Home Building for Aged Care Facilities, Albany

Cooling Tower - Cooling Water FRP Piping System Repair Rapid Turnaround

Nursing Home Building for Aged Care Facilities, Kalamunda

PROJECT MANAGEMENT