Pneumatic Pressure Test On Air Cooled Condenser (ACC) System
Fully executed high volume, low pressure compressed air test on first attempt, first of its kind tested in the USA.
Location
Gulf Coast, Louisiana
Scope of Work
A major Industrial contractor required a high volume, low pressure pneumatic pressure test as part of pre-commissioning activities on a new Air Cooled Condenser (ACC) system in a carbon black plant. Test procedure included a 90 minute pressure up time with a 4 hour hold utilizing multiple digital pressure and temperature measuring instruments with an extremely high level of accuracy. Stable ambient temperature required with no more than a 5 degree change throughout the system during testing. Target test pressure was 4.35 psi with over pressurization safety devices manufactured and set to 5.5 psi. BlueFin sourced equipment and fully executed pressure test on first attempt.
Challenges
Only a 1 psi test pressure range between target test pressure and overpressure safety devices.
Meeting stable temperature requirements with a variable ambient temperature and heat created by air compression.
Sourcing instruments with extreme accuracy: Temp devices with +/- 0.4 % full scale, Pressure devices with +/- 0.15% full scale
Meeting pressure up time requirements without safety device or system over pressure.
Multiple monitoring devices in different areas on scaffolds and man lifts needed to be received and recorded in under 5 minutes.
SIMOPS with construction and operations personnel.
Critical startup date established by operator.
Plan of Execution
Project Planning & Preparation
Perform job walk with client.
Identify equipment layout, testing terminal points and instrument quantities and locations.
Create project specific test procedure.
Custom build temporary test header to meet testing requirements.
Source test instruments with required accuracies.
Onsite project management support.
Phase 2 Remediation Effort: Engineered Pig Train Consisting of Seawater, LiquiGel® Technology, Chemicals, and Aggressive Mechanical Pigging
Rig up compression equipment, manifold, instruments, probes, and rupture discs.
Route all data recording equipment back to test cabin.
Pre-planned controlled pressurization and depressurization process.
Execute test per project specific test procedure. Record all electronic temperature, pressure, barometer and manometer results.
Relay results to manufacturer rep for test acceptance prior to depressurization.
Technical Achievements & Benefits
First time an ACC of this size and type tested in the USA.
Successfully completed pressure test at first attempt, which is a rarity per the manufacturer standards.
Provided technical expertise for equipment set up, layout and use to meet procedure requirements without any adverse effects on pressure limits and temperature stabilization.
Technical competency identified potential problems with general test plan. Onsite project management provided a mitigation plan in to meet system parameters, manufacturer specs and regulatory requirements.
Successfully completed testing ahead of schedule without any safety concerns or environmental impact.
