In fall 2016, we started the project, whose implementation lasted 10 months. It concerned the relocation of five oil tanks and one glucose container.
Therefore, it was necessary to re-install utilities. It was a perfect opportunity for the factory to improve the transmission installation system and fully automate the process of dosage and transportation. However, it was necessary to supply not only oil and glucose, but also all process elements, such as hot water, and provide a return way therefor.
A new part of the hall, with a special area for handling tankers, was the place for containers. The distance from the place of oil receipt was so long that we build over 750m of DN50/DN65 double-wall for the oil only, around 100m of DN80/DN100 double-wall for glucose, and over 500m of pipelines for hot water.
The construction started with putting the pipelines at a place where the tanks were to be moved. Our purpose was to reduce the downtime in the production process, therefore, the pipelines were constructed during the ordinary operations of the factory. When all installation systems were established under our supervision, the subcontractor with crane heavy equipment moved the containers (each 25m3) to the agreed place. After an attempt to operate the installation system and connected containers proved successful, we could finish the first stage of the project.
Due to the connection of the hot water pipeline with the heat exchanger located in the boiler room, we adjusted the pipe in such a manner that it may handle a larger number of utilities.
All works were perfectly synchronized with the suppliers of fittings, production, transport of containers and company preparing the process automation.
The last stage was to prepare the insulation for all pipelines. Each element was insulated with mineral wool in wall made of polished stainless steel 0.4mm. All steel elements of the wall were prepared by our own means, whereas the segment knees were individually developed and adapted to the conditions of potential installation of insulation materials. 55% of insulation sections were consequential. We cut all segment knees and T-connectors using our water jetter, so we had control of the knee radius and length of the connector.
98% of the works were performed during regular production operation in the factory, which was a great advantage for our client. For us, the challenge was the work of fitters and welders, without any production downtimes of the client, at places with higher OHS standard.