Dismantle and Re-Erection of two 75’-5 Dia x 250psig Spheres

The (2) 75’-5 DIA x 250 psig LPG spheres were originally constructed at a LPG terminal in Cuenca, Ecuador in 2016. This terminal was located in the Andes Mountains at 8,200 feet above sea level. The spheres became compromised due to the mountain range’s instability and therefore it was determined they needed to be relocated to another location. The new location chosen was Chorillos, Ecuador which is approximately 300 kilometers from the original terminal. As a result of the need to relocate the spheres from a remote and mountainous location, there were significant challenges to be met throughout the planning process.

First, a sphere assessment to determine the overall integrity of the existing spheres prior to cut-down and re-erection was completed, followed by a sphere dis-mantling plan to account for easily re-assembling and transport through the rough terrain. Once the material arrived at the newly installed foundations, the material was laid out in accordance with the labeling system to ensure proper re-assembly with special care taken to measure and verify the roundness tolerances were met. The welding process included the re-beveling of plates, proper preparation of all joints and preheat of all pressure boundary steel during the welding process. NDE plans for inspection, examination and testing were developed that met current code requirements which included 100% volumetric examination of all new joints. A field PWHT was performed on each vessel once re-assembly was completed at a temperature of 1,050 degree Fahrenheit.

The operations team utilized experienced supervision to hire, train and lead local craft labor to complete this work. Construction planning was critical to ensure the safe dismantle, transportation, and re-erection of the (2) spheres while upholding a zero-incident record throughout the project and meeting high quality and safety standards. The construction and QA/QC team implemented thorough traceability practices to ensure that each plate was re-installed to its initial position within each sphere. The entire dismantle and re-erection process was witnessed by a certified ASME inspector.

This project demonstrates true value in the adaptability and modification of steel structures due to the overall uniqueness and successful completion of the (2) spheres now located in the LPG Facility in Chorrillos, Ecuador.