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Industrial process piping across a live chemical plant.

Multi-service process and utility piping racks fabricated, installed and pressure-tested across a chemical plant that continued to run while we worked.

Pipe length— m
Duration— months
Services7 utilities
ShutdownLive plant
The brief

Seven utilities, one rack — across a plant that couldn't shut down.

The challenge

The client's chemical plant needed a new multi-service piping spine to feed a planned production line — process water, chilled water, compressed air, nitrogen, steam and two utility services on a single shared rack. Production on the existing line could not stop. The site footprint allowed almost no slack for fabrication on-site, so the bulk of the work had to be done off-site and craned in.

What we delivered

  • Engineering of the full piping rack, supports and isolation valving
  • Off-site fabrication of stainless and carbon steel spools, with documented dye-penetrant and X-ray weld inspection
  • Phased on-site installation around live operations, with hot-tap connections where required
  • Pressure testing per system, witnessed and signed off line-by-line
  • As-built drawings and a maintenance package handed over with the works

How the EPC lifecycle applied

Engineering. Routing optimised to minimise tie-in points to live process — fewer cuts, less risk.

Procurement. Materials sourced to ASTM/IS standards, mill test certificates retained on file for every spool.

Installation. Crews worked in phased windows aligned with the plant's daily operations rather than against them.

Testing & commissioning. Hydrostatic and pneumatic tests per service, results documented and witnessed by the client's QA team.

AMC. Periodic ultrasonic thickness checks and gasket replacement included in the maintenance schedule.

Outcome

Zero unplanned plant downtime during the install window. All seven services pressurised, signed off and handed over on schedule. Outcome metrics to be added

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