The Challenge
AsBuilt was contracted to provide a complete engineering package for the removal of fuel gas heaters, isolation valves, and associated electrical and instrumentation equipment at a power plant. The heaters had never been commissioned and were identified as a potential gas leak risk while also adding unnecessary maintenance burden.
The heaters and associated components were mounted on skids and tied into large-bore, high-energy piping systems. Their removal required careful planning to ensure system safety, maintain structural integrity, and avoid introducing excessive stresses during and after valve replacement.
The Solution
AsBuilt performed detailed engineering to support the safe removal and replacement of large-bore, high-energy valves and piping. This included planning cut locations, defining removal sequences, and designing temporary pipe supports to maintain system stability during demolition.
Permanent pipe support modifications were evaluated and implemented as needed. Piping and support stress analyses were conducted to verify that the new valve installation would not exceed code-allowable stress limits under operating, thermal, and support conditions.
3D laser scanning was used to capture accurate as-built conditions of the piping and structural steel, providing a reliable basis for modeling, analysis, and installation planning. Scan-based models supported coordination across engineering, construction, and safety teams.
Key Outcomes
- Safe Removal of High-Risk Equipment
Uncommissioned heaters were removed without compromising system integrity. - Code-Compliant Valve Replacement
Stress analysis confirmed all new piping and supports met allowable limits. - Reduced Construction Risk
Temporary and permanent support requirements were defined before field work began. - Improved Coordination
Scan-based models aligned engineering intent with installation execution.
Deliverables
- Pipe Stress Analysis Report
- Stress Analysis Model Files (CAESAR II)
- Structural Support Stress Analysis Report
- Registered 3D Scanning Point Cloud
- Navisworks Model of Piping and Structural Steel
- Isometric Drawings
Why It Matters
Fuel gas systems demand absolute precision. By combining accurate as-built data with rigorous engineering and stress analysis, AsBuilt reduced safety risk, ensured code compliance, and delivered a clear, executable path for removing unnecessary high-energy equipment.
