Sulphuric Acid Tower Distributor Piping Change-Out

LOCATION

Alberta, Canada

INDUSTRY

Industrial Processing / Chemical Processing

Project Overview

Our specialist maintenance team was engaged to complete a critical Sulphuric Acid Tower Distributor Piping Change-Out at a major industrial facility in Alberta, Canada.

The project involved working within a highly hazardous, non-life-supporting environment to safely access, remove and replace existing distributor piping and associated components. Due to the challenging operating environment and restricted access, the works required specialist personnel, purpose-designed respiratory protection and fully encapsulated chemical-resistant suits.

Working to NoramSX™ specifications, our team successfully completed the piping change-out and reinstatement of ceramic packing, enabling the client to return the plant to operation with reduced shutdown downtime.

Scope of Work

The project scope included:

Removal of approximately 950 mm of ceramic packing to provide access to the tower downcomers.
Unbolting and removal of the existing distributor piping.
Assembly and installation of the new distributor piping.
Installation and connection of the new piping to the downcomers in accordance with MONDI™ specifications.
Installation of new ceramic packing following completion of the piping works.
Inspection and reinstatement of the work area.
Completion of all activities within the scheduled plant shutdown window.

Specialist Working Environment

The nature of the work required our team to operate within a non-life-supporting environment, presenting significant challenges associated with hazardous atmospheres and sulphuric acid exposure.

To maintain the highest level of protection throughout the works, personnel operated in fully encapsulated chemical-resistant suits supported by dedicated breathing-air apparatus.

Our experienced team was able to combine specialist confined-space and hazardous-environment practices with the technical requirements of sulphuric acid plant maintenance, ensuring the work was completed safely and efficiently.

Project Resourcing

The project was delivered by a dedicated team of experienced shutdown and maintenance personnel, supported by specialist equipment and safety systems appropriate for the working environment.

Key resources included:

Experienced shutdown and maintenance personnel.
Fully encapsulated chemical-resistant suits.
Breathing-air apparatus.
Specialist tools and equipment for piping removal and installation.
Ceramic removal and reinstatement capability.
Hazardous-environment safety and monitoring equipment.
Project supervision and coordination.

Key Activities

The project incorporated a range of specialist activities, including:

Fully encapsulated suit operations
Breathing-air apparatus
Sulphuric acid (H₂SO₄) works
Shutdown maintenance
Piping removal and installation
Ceramic packing removal and reinstatement
Downcomer access and connection
Specialist hazardous-environment maintenance

Project Achievement

Despite the challenging working environment and technically demanding scope, all works were completed safely ahead of schedule. This allowed our client to return the plant to operational status earlier than planned, helping to reduce overall shutdown downtime and minimise disruption to plant operations. The successful completion of the project demonstrates our ability to deliver complex maintenance activities in high-hazard environments while maintaining a strong focus on safety, technical compliance, quality and schedule performance.

Delivering Specialist Shutdown Solutions

This project highlights our capability to undertake high-risk sulphuric acid maintenance and shutdown activities where specialist equipment, experienced personnel and disciplined execution are essential.

From hazardous-environment access through to piping replacement and ceramic reinstatement, our team provided an integrated solution that enabled the client to complete a critical maintenance activity efficiently and return the facility to operation ahead of schedule.