Projects / High-Pressure Steam Ring Main & Condensate Overhaul
CASE STUDY // PIPING•Industrial Polymer Chemical Plant•12,000 m² chemical synthesis plant
High-Pressure Steam Ring Main & Condensate Overhaul
FIELD RECORD // MECHANICAL PIPING, STEAM & PUMPS
Engineering Performance Metrics & Delivery Parameters
Design Pressure12 bar gauge
Hydro Test18 bar hold
Weld Rejection0% RT fail
Monthly Savings$3,800 steam
FIGURE 1.0 // AS-BUILT SCHEMATICVerified by Lead Discipline Engineer
STRUCTURAL CAD // CONNECTION DETAILDETAIL-STR-401
The Technical Brief
Replace 320 metres of leaking 6-inch 12-bar saturated steam main piping, upgrade pressure reducing stations, and install thermodynamic steam trap stations with automated condensate monitoring.
Site & Operating Constraints
Steam header supplies reactors holding temperature-sensitive chemical batches. Cutover window was tied strictly to boiler statutory cool-down cycles.
Execution Methodology & Works Delivered
- Prefabricated 48 flanged spool pieces in ASTM A106 Grade B seamless carbon steel
- Certified 6G TIG root and SMAW cap welders executed 74 tie-in welds on site
- Conducted 100% radiographic testing (RT) and hydro-tested the assembly to 18 bar (1.5x design)
- Installed pre-formed mineral wool insulation with heavy-gauge embossed aluminum cladding
- Calibrated Spirax Sarco PRV stations and commissioned steam traps with acoustic leak monitors
Verified Outcome
Eliminated $3,800 monthly steam loss, stabilized process reactor supply pressures to within ±0.1 bar, and received Labour Department statutory boiler inspector certification.
Discuss Similar Facility Scope
If your plant requires similar switchgear cutover, refrigeration overhaul, or cleanroom installation, speak directly with our team.
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Industry SectorManufacturing Plants & Heavy Processing
Core ServiceMechanical Piping, Steam & Pumps
Total Duration4 weeks prefabrication, 68 hours on-site cutover
Downtime Allocation72-hour annual boiler inspection window