Case Study: Expansion of speciality chemicals plant
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Contract Scope:
Project Background
The Perstorp Group is a world leader in several sectors of the speciality chemicals market. It has 127 years experience and now employs approximately 2,200 people across Asia, Europe and North America.
When the manufacturer decided to upgrade its Warrington facility, Boulting Group successfully secured the contract, which included and expansion of the Caprolactone Monomer and Polymer plants.
Project Details
The first contract was solely Mechanical in nature. Boulting Group then went on to secure further Electrical and Instrumentation work across five phases.
- Contract Value: £6 million (approx.)
- Contract Duration: 14 months
- Location: Warrington
Scope of Work
Mechanical
Mechanical scope primarily focused on the fabrication, much of which took place at Boultings mechanical workshop in St. Helens, and installation on the project.
Contracted works were broken down into phases and issued in packages. Initial installation started form 20% design. Works were assessed in order of constructability and issued as design packages. Towards the end of the contract emphasis changed to pre-commissioning/completion.
Progress was continually reported back to ensure that the client was kept up to date.
Fabrication/Installation Specifics
- Various columns
- Pressure vessels
- Pumps
- Associated pipework
- Instrumentation
Electrical and Instrumentation
The Electrical and Instrumentation works were split into phases with each phase awarded individually. This meant that the E&I team had to estimate and compete for each phase separately, making it very difficult to plan ahead.
Despite uncertain circumstances and strong competition, Boulting E&I team successfully secured and completed the following works:
Phase 1:
Installation of the main containment system from the switch room to the new Monomer extension.
Phase 2:
Installation of main power and control cables from the new Monomer switch room.
Phase 3:
Installation of instrumentation cables and containment to field control equipment.
Phase 4 and 5:
Installation of main containment and cabling to the tank farm and water cooling tower.
Phase 6:
Installation of external light fittings, lighting containment and cabling on the tank farm and main Monomer structure.
In total the E&I team installed over 55,000mts of cable, 19,000mts of containment, 1,500mts of racking (size ranging from 900mm t0 15,00mm) and 5,000mts of supporting steel.
Full Services Supplied
- Project management
- Structural and Mechanical Engineering Design
- Fabrication of free issue carbon steel pipework
- Mechanical and Electrical installation
- Pre-commissioning, commissioning and testing
