LTC’s Larsen & Toubro Heavy Engineering Division (LTHED) was awarded a US$35 million project to design, manufacture, and supply the reactor-regenerator (RR) package for two residue fluid catalytic cracker (RFCC) units at the RAPID refinery project for PETRONAS in Malaysia.
The RR package includes the reactor, regenerators, riser, spent catalyst stand pipe, and all other association equipment and piping plus supports and structural hardware.
The refinery project involved many complexities including tight deadlines and very high operating temperatures of 800 to 900 degrees Celsius, and pipe ranging from ½ inch to 82 inches in diameter. LTC also had to interpret two ASME piping codes simultaneously.
Early finalization was required so that high thickness (up to 150 mm) plates, custom expansion joints, and springs could be ordered early. Any delay would negatively impact other engineering deliverables.
With Intergraph® CAESAR II®, the group could determine material specifications and order early, saving significant time, and quickly check for clashes to decide pipe routing, expediting client approvals, all without a 3D model.
“CAESAR II made analysis extremely simple, time-saving, and cost-effective. It made the design safe and reliable, and without manual errors,” explained Pradeep Darji, lead pipe stress engineer and general manager at LTHED.
Analyzing components in other FEA software would have taken a very long time. Then simulation and further re-run would have caused more strain on the short timeline.
Without CAESAR II, manual analysis errors and schedule overruns were common as were design problems, resulting in wasted time and added expenses. There could also be disputes among the site execution, engineering, and design teams. CAESAR II also helped avoid an unnecessary expansion joint, saving additional material costs. The team extracted isometric drawings from CAESAR II to prepare fabrication drawings, meeting a very tight schedule.
“With CAESAR II, we saved US$500,000 on expansion joints – 1.5 percent of the total project cost,” Darji added, “and we also saved 20 percent in piping engineering man-hours with the fast analysis and automation CAESAR II provides.”
LTC received the 2016 CAESAR II Drivers of Success Runner-Up Award for its use of the software. The annual Drivers of Success competition recognizes innovative applications of Intergraph products, impressive project results, and significant benefits from collaboration among disciplines and the integration of the products.