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Energy & petrochemical
Sasolburg Petrochemical Pipe Racks & Access Rig
Multi-tier pipe racks, distillation column access towers and explosion-proof stairways for high-temperature synthetic fuel processing, held to ±1 mm over a 20 m span for critical piping tie-ins.
Project data
- Client
- Free State Synthetic Fuels
- Location
- Sasolburg, Free State, South Africa
- Year completed
- 2025
- Tonnage
- 4 300 t
- Tolerance
- ±1 mm over 20 m span
- Steel grade
- S355JR / S355J2 carbon steel
- Coating
- ISO 12944 C5-M duplex system
- Hazard rating
- Zone 1 explosion-proof detailing
- Programme
- 16 months, phased shutdown tie-ins
The challenge
Pipe-rack steel that misses tolerance forces field modification of process piping — the single most expensive failure mode on a refinery tie-in, and one that has to happen inside a fixed shutdown window.
Our solution
Every tie-in elevation was surveyed by 3D laser scan and imported into the Tekla model, so the fabricated steel matched as-built conditions rather than the original design drawings. Critical spans were trial-assembled and dimensionally verified against the point cloud before release.
The outcome
All 214 piping tie-ins landed within tolerance on first fit. The shutdown window closed on schedule with no field rework of primary steel.
Engineering highlights
- ▹3D laser scan reconciled against the Tekla model
- ▹±1 mm tolerance verified by trial assembly
- ▹214 piping tie-ins, all correct on first fit
- ▹Zone 1 explosion-proof access and stairway detailing
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