Ingenuity Magazine Summer 2021

The 54,000 lb. scrubber tower tank, already scheduled for demolition within the next 10 months, is used to convert a hazardous gas into an organic compound. A tank with cracks could be potentially very dangerous as the gas that’s being converted is flammable and exposure can cause harmful effects to workers. With safety the top priority, Pond recommended keeping liquid in the tank tower for stability and evacuating the facility until it could be determined as safe for occupancy. Simultaneously, Pond deployed a response team that included a mechanical integrity engineer, structural engineer, process engineer, and construction manager. Quick response from multi- function team brings real time solutions Arriving on site within 12 hours of the emergency call, the Pond team identified the structure as a fiberglass tower, built in multiple sections, with an insulation wrap. Pond’s immediate responsibility was to install emergency bracing so the base of the tower could be observed safely. The bracing was designed and fabricated, mitigating the risk of catastrophic collapse. The scrubber was drained by a hazmat team. Working on parallel paths, the Pond team of structural, mechanical integrity and process engineers assessed the tank to determine possible causes of the cracks while looking for emergency and long-term solutions that would safely return the plant to full operation. Pond’s process team worked from “worse case” presumptions so that, should the structural and integrity teams determine that the scrubber must be decommissioned, an equipment replacement option was readily available. Procurement and construction managers stood ready upon notice. Returning to full operation The shapes of the cracks indicated a torsional force on the surface of the insulation. The location indicated that this force most likely centered around the nozzle connecting to the scrubber reactor. The Pond team found that the most likely cause of the cracks was the additional stresses created from failure of a recent joint replacement, perhaps aggravated by thermal stresses from pressure-washing activities. Recommended emergency changes were implemented, thus allowing the plant back into full operation. The plant is conducting routine inspections while Pond makes process changes that will ultimately allow for removal of the scrubber. The quick and highly coordinated response allowed the plant to return to full operation with relatively minimal downtime. Alex Holbrook, Mark McNaron, Anthony Chinn, Joe Brejda, and Malick Sangare EMERGENCY RESPONSE RETURNS PLANT TO FULL OPERATION SAFELY & QUICKLY Multi-dimensional assessment requires teamwork STRUCTURAL ENGINEERING PROCESS ENGINEERING MECHANICAL INTEGRITY O ne of Pond’s long-term clients, a medical device manufacturer, was conducting a routine plant inspection and discovered insulation cracks in a scrubber tower’s tank. The client recognized the potential hazards and immediately called Pond. "Working on parallel paths, the Pond team of structural, mechanical integrity and process engineers assessed the tank to determine possible causes of the cracks while looking for emergency and long- term solutions." 10 Pond | www.pondco.com

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