Overview
A chemical processor needed 1,200 feet of new process and steam piping tied into a live plant — 140 welded joints across carbon and stainless, installed during a 12-day turnaround window. First hydrotest passed with zero leaks.
The Challenge
Half the tie-ins touched operating lines, so every hot tap and weld had to be sequenced around production with no room for a do-over. Stainless roots demanded full purge protection in tight overhead positions.
Our Approach
We pre-spooled everything possible in our shop, numbered every joint on the isometrics, and staged two 6G crews in sequence — fit, purge, root, fill. Each weld was mapped to its welder and purging log before the next joint started.
140
Joints welded
0
Leaks at hydrotest
12 days
Turnaround met
Related Work
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