Confidential Client

The Customer was provided a lump sum turnkey engineering, procurement, fabrication, and construction project, including paint, for two (2) new 66’-6 diameter Vinyl Chloride Monomer Storage Spheres at the Customer’s existing facility.

The spheres were designed in accordance with ASME Section VIII, Division 1, 2021 Edition and code stamped and registered with the National Board. Each sphere was designed for an internal pressure of 100 psig and an external pressure of 0.25 psig.

There were two crews used to erect the spheres in a sequential order, allowing for the most efficient fabrication and field erection methods. The project (field erection and paint) took approximately 14,650 man-hours to complete with zero safety incidents.

The NDE testing for these spheres was 100% RT. The total quantity of weld length was in excess of 9,000 inches. A weld acceptance rate of 95% or above was maintained on both spheres.

Uniquely, this project required for the performance and associated documentation for recording all temporary attachment and lift lug locations during the construction process which added to the project complexity.

The painting of the spheres was self-executed. The full primer was shop applied before shipping to the field. This limited the field blasting for the Customer and reduced field waste in the blasting process.

The testing of the spheres was included in the scope and was a team effort with the Customer sourcing water efficiently from nearby water sources to conduct a seamless hydrotest for each sphere.

This project was challenged as the ground elevation of the sphere locations was only 5′-0 above sea level and there were several large rain events over the course of project activities that had the potential to significantly delay the overall completion of the spheres. However, the field crews worked in concert with the Customer to improve the ground and fortify the assembly area (with the use of substantial matting) so that the site had solid work surfaces during and after all wet periods mitigating challenging soil conditions.

Overall, the Customer was pleased with zero safety incidents and the final completion dates achieved for these spheres.