Vessel not resting on concrete saddles

[Gillani]

Hello,

There is a horizontal flare KO vessel (dia 4 mtrs) which was designed in a unique way and installed wrongly. The vessel was designed to be resting on 180-deg concrete saddles and had lugs designed to be bolted on top of those saddles. During construction (approx 12 yrs ago), the foundation sides were built too high and when vessel was installed, the shell did not touch the saddle curve at any point but was 170 mm above it at 6'o clock (see attached pic). The vessel was accepted in service and nobody bothered to raise any red flag during 12 years of operation.

What options do you guys propose to resolve this installation error?

 

[r6155]

Is there any damage to the PV?

Regards

 

[Gillani]

Not to the vessel, but the top of concrete (where lugs are bolted) has cracked.

Plus this vessel must have a mandatory regulatory hydrotest after 10 yrs of service.

 

[LittleInch]

Make two bits of form work out of plywood, seal the edges and put in non shrinkling grout from the top?

Or pump it in from the bottom though a hole in the form work.

Remember - More details = better answers
Also: If you get a response it's polite to respond to it.

 

[Gillani]

Can grout take the vessel operating load of 95 tons and hydrotest load of 224 tons? So some reinforcement must be added in the gap?

Have you guys come across such a situation before in your experience?

 

[r6155]

Free expansion and contraction must be maintained.
Consult with a civil engineer if the saddles can be cut to the required dimension without any risk, with the use of 2 cranes during this work.

Regards

 

[Gillani]

Cutting the saddles down to size is not an option because this is HP Flare KO vessel connected to relief piping network.