Blog

The value of the explosives engineering discipline

The controlled use of explosives is, on occasions, selected as the preferred demolition methodology for projects, as it can provide a safer and faster alternative to bringing large structures down mechanically over a period of several months.

Therefore, despite the seemingly ever-increasing size of long-reach excavators, explosives still have a crucial role to play in the safe and efficient execution of complex demolition projects. But do people realise the important and exciting nature of the discipline? And are enough young adults considering a career within the explosives industry?

These are topics the RVA team was asked to cover in a detailed article for Explosives Engineering, the official journal for The Institute of Explosives Engineering (IExpE). The full piece, which describes what a career in explosives engineering involves and what value explosives brings to the modern-day demolition environment, is shown here in its entirety….

“The world of demolition is becoming increasingly varied. Assets across the globe are reaching their end of life and there is an unprecedented need to demolish these safely, cost-effectively, in an environmentally sound manner, and often within strict programme constraints. But as the nature of demolition projects continues to evolve, so too do the possible methodologies used to carry these projects out.

Whilst there has been limited radical advance in demolition technology over the last few years, plant manufacturers are managing to build larger machines capable of dealing with taller structures. In 2009 for example RVA Group oversaw the mechanical demolition of a 50m chimney stack that was brought down using an excavator with a 60m telescopic boom and even this machine is dwarfed by more recent models.

However, it isn’t all about size and in certain instances the controlled use of explosives is still selected as the preferred demolition method. Often this is because it provides a safer and faster alternative to demolishing structures of all types, whether they be high-rise residential dwellings or steel framed industrial building or process plants. A structure may be too tall or complex for conventional machinery for instance, but the alterative of manually dismantling it piece by piece would necessitate operatives working at height for extended periods of time. Not only may this have implications for the project programme, but the risks posed to the operatives is also unnecessarily heightened.

There are also many other potential influencers. The structure may have become unstable due to working life stresses, concrete decay or even poor build quality, so mechanical demolition could simply be too dangerous; the structure might be positioned in close proximity to assets that require absolute protection; environmental and/or community disruption may need to be kept to an absolute minimum; and cost can even play a deciding factor too.

Ultimately though increasingly sophisticated explosives systems tend to ensure greater predictability of the outcome. Last year for instance, RVA Group project managed and coordinated the safe demolition of a 17-storey tower block in Greenock, Scotland. Meticulous planning and robust scientific methodology was needed to protect a nearby Network Rail infrastructure, the boundary of which sat just 3m from the building. Disruption to the electric rail commuter services also had to be kept to an absolute minimum.

The controlled use of explosives posed the most suitable methodology by far for bringing down the tower – not only would the alternatives of mechanical demolition or floor-by-floor dismantling have increased the possibility of debris falling onto the railway line, but a longer demolition period would have heightened the potential risk for project workers and the community. Furthermore, this demolition plan meant that only one railway line possession was needed and as the blowdown took place at night, commuter service disruption was minimal. At the time of the project the client – social landlord River Clyde Homes – praised the fact that site operations were carried out safely, the integrity of Network Rail’s assets was not compromised and ultimately the demolition programme was a great success.

Having assessed a structure and considered the suitability of explosives methodology, the explosives engineer then has a series of justifications to make with regard to a suite of factors including project safety, cost and programming.

Before proceeding with any demolition exercise, the engineer must therefore be able to conclude that the level of risk presented by the controlled use of explosives is manageable and acceptable. Of course every single job presents specific challenges, so extensive preparatory work is always crucial. Numerous precautionary measures can be employed:

  • Construction materials and even process residue samples can be taken to assess the degree of contamination – if any – within a given structure. Decontamination strategies can then be devised and executed accordingly;
  • Test blasts can be carried out prior to the blowdown to validate the design of the charge weight, drilling pattern and primary protection;
  • Vibration specialists can determine that the demolition will not cause disruption or damage to the surrounding environment.
  • Before a blast is carried out the project team should also liaise closely with all relevant external stakeholders, including the community, local authority and emergency services. Because the explosives engineer takes ownership of the project when the explosives phase is underway, responsibility for risk assessments, exclusion zones and contingency and misfire arrangements must also be assumed. Once a structure has been demolished, the rubble should be inspected to ensure inherent stability and to certify that no undetonated explosives remain. Debris and dust should also be cleared from the surrounding area – not only does this protect the environment but it allows any site neighbours to return to normality as soon as possible.

Demolition is only one very small sector within the explosives industry, but there is still great scope for the discipline to excel within this engineering arena. The number of large-scale production facilities being closed worldwide remains staggering, and there is a need to clear these sites safely, cost-efficiently and with minimum environmental impact. Even regeneration projects that have been temporarily shelved as a result of economic difficulties will need to be addressed in the near future.

There is no reason why the role of explosives engineering within demolition cannot therefore have longevity. Yet unfortunately there are very few experts within this compelling field and the evidence of new blood wanting to make a career in this sector is also sparse.

There are two main elements to the explosives engineering discipline. Of course there is the need to truly understand pure explosives technology – how to handle them safely, the different types, how they should be stored, how they work and how they can best be used.

But engineers are simply utilising the explosive product as a tool to effectively achieve an objective. To be of value, pure explosives knowledge must therefore be aligned with a practical understanding of the defined profession, whether this is demolition, mining, tunnelling, quarrying or special effects for example.

So in demolition the engineer should also have an understanding of structures and a comprehension – perhaps with the input of other specialists such as structural engineers – of what the project needs to achieve in terms of collapse. The engineer must analyse and design where to place the detonator, how much charge to use, where to place the charge, what delay sequence to employ, what detonation methods to implement in order to reduce the quantities of explosives required, and what the suitable exclusion zone should be.

The considerations are numerous, and the competencies of a skilled explosives engineer multi-layered. An appreciation of the product science should be complemented with a level of articulacy and comprehension with the discipline to follow creative yet meticulous procedures and methodology. A respect for the power of explosives, within any field, is also essential.

But knowledge grows with experience, and the importance of continuous professional development cannot be underestimated. Where possible engineers should attend educational seminars and events not only to learn more about advances in explosives, but to remain abreast with safety systems and standards, environmental issues and ever-changing legislative control measures too. A true explosives engineer will have empathy for all related project factors.

Professional bodies such as the IExpE ensure that explosives engineers, scientists, logisticians, academics and legislators alike are recognised in terms of occupational competence, as membership to the Institute is earned by achievement not subscription. All industry specialists should equally acknowledge their duty to help shape industry developments and nurture the explosives engineering talent of the future.

To what extent people beyond the industry understand the exact science and extensive preparation involved in an activity which appears to last less than 10 seconds, is difficult to say. However the truth is that a career in explosives engineering – whilst hard work – will always offer new, exciting and challenging opportunities that are perhaps not comparable to those in many other professions.”

Share

RVA knowledge in high demand

The specialist engineering expertise and experience of RVA Group has once again been sought after by the industry’s leading technical journals.

Last month RVA provided a detailed insight into the ways with which the company’s impartial consultancy service can breathe life into shelved demolition projects. This ‘demolition turnaround’ contribution – included in the very first of The Construction Index’s new in-depth features – can be read in full below:

“Some people would argue that the future looks tough for demolition, whereas others would suggest that now is the time for the discipline to shine. Here the specialist engineering consultancy team from RVA Group examines the current marketplace and shares their views as to a very important tool that is changing the future of demolition projects across the globe…

It is widely acknowledged that demolition – like many areas of the construction industry – has experienced an extended period of difficulty as a result of recent economic turbulence. Some well-established contractors have entered into administration because of absent work and increasingly pressurised margins, and whilst some companies report continued robustness, market confidence still seems questionable.

However the apparent lack of active demolition projects doesn’t accurately reflect the number of sites, plants and assets that are lying redundant throughout the UK, and beyond. The number of production facilities being mothballed, rationalised or permanently closed down across the globe remains staggering, so in theory the work should exist. Yet many decommissioning and demolition projects have been shelved due to the anticipated cost of undertaking what is often perceived as an unnecessary exercise, or certainly one that can be delayed until a fiscal improvement is seen.

Naturally organisations wish to avoid non-essential spend, but postponing projects that are deemed unaffordable is not always the most appropriate solution. They will inevitably have to be tackled at a later date and in most cases at an overall increased cost due to continuing liabilities such as hazardous material containment, security provisions, regulatory compliance fees, care and maintenance costs , together with the burden of inextricable overheads such as local authority building rates.

Some companies initially try to sell their plant in-situ in an attempt to pursue a relatively ‘pain-free’ site exit and where possible protect employees’ jobs. But if a buyer is not found they can then struggle to know what to do next.

Difficulties lie in making informed decisions about the future, especially at a time when pressures are mounting or there are gaps in knowledge. Independent tools like feasibility studies will therefore play an ever-increasingly crucial role in the development of organisations’ redundant asset management plans and consequently the possible level of demolition work within the industry.

Drawing upon specialist engineering experience, sector knowledge and commercial awareness, feasibility studies provide an unbiased, clear and realistic view as to the true liability or indeed opportunity of a decommissioning and demolition project. EHS, commercial and financial factors associated with the given site and current marketplace, are all considered. This means assessing realistic costs, potential hazards and risks, the status of the supply chain, the commodity value of scrap, technological trends and requirements in emerging market, waste management obligations, required resources, relevant legislation, and programme and scheduling constraints.

These studies generate a number of unique, robust and cost-effective options or solutions that companies may not have considered or even deemed possible. They also provide sufficient data and confidence to pursue a given route whether that be:

  • The dismantling of plant for re-sale, re-erection and operation elsewhere;
  • The demolition of plant, where it is often possible to generate an income stream due to the prevailing value of scrap. Not only does this mitigate ongoing and unacceptable levels of liability, but in some cases the project can be self-funding, if not even profitable;
  • The mothballing of plant;
  • Or, a combination of the options above.

These widely-regarded strategic management tools remove an element of the unknown and provide an insightful starting point from which innovative, value-adding and considered business decisions can be made. It can be the difference between a project getting started or not starting at all.

It is important to remember though that demolition is not always a straightforward process; it is an inherently hazardous activity. The goal should be to maximise return on assets where possible and indeed safe to do so. However factors such as plant age, former processes, recovery cost, testing, market forces and commercial competition will all form part of the decision as to what should and shouldn’t be salvaged.

Devising a cost-effective project plan certainly doesn’t mean cutting corners, because EHS excellence must remain the non-negotiable priority. Nor does it mean avoidance of legislative compliance. It just means utilising a true understanding of the engineering environment, anticipating possible challenges and resolution methods, and evaluating factors that may otherwise have remained unconsidered.

Demolition as a profession has a bright future, and there is no reason why the expertise of some of the UK’s most talented specialists will not be increasingly sought overseas too – we’ve already seen it start to happen. What is important though is the development of close-working, knowledge-based relationships with clients, so that the safest and financially optimal solutions are considered and understood.”

Share

Scientific approach for Finnish BASF project

The world’s largest chemical company BASF has commenced the dismantling and demolition of its Kaipiainen polymer production facilities in Finland. The activity is part of a strategic consolidation which will allow the company to focus its attention on alternative worldwide manufacturing, following its acquisition of chemical company Ciba in 2009.

To project manage the complex process, BASF has appointed UK-based specialist engineering consultants RVA Group. A team from RVA has spent five months helping BASF prepare for the project and will now oversee the safe execution of the works.

With their extensive expertise of diverse decommissioning projects, RVA has already directed the full tender process, assessing submissions from contractors across Europe. Having appointed a Finnish team of experts to carry out the demolition work, RVA will now remain on site throughout the entirety of the three month project execution to ensure it runs smoothly and safely.

But this is not just a straightforward site clearance exercise. Whilst major redundant plant items are to be dismantled for recycling, some external and internal elements of the production area have been cherry-picked by a new company that will store and distribute chemicals from this site. RVA must therefore ensure the safety, protection and integrity of these valuable assets which include large storage vessels (in a tank farm only metres from the demolition area), and a two-storey building with two process areas separated by a large warehouse. Vessel removal is taking place in both process areas, but a significant number of reactors are also being retained.

As the next occupants are set to move onto the site before the project’s completion, RVA will use their sector-specific experience to ensure that appropriate safety standards and methodology are applied.

Working closely with the appointed contractor, RVA will also safeguard the activity of the three industrial companies that currently share the BASF site. Whilst there is no fenced boundary separating the operational companies from the demolition works, it is essential that minimum disruption is caused and exemplary safety standards are maintained. Central facilities such as a boilerhouse, waste water treatment plant and an essential rail freight line must be protected and whilst some services have been re-routed, it is crucial that the supply of raw materials remain uninterrupted.

A 53 tonne excavator with a 25m reach and a 2.3 tonne shear will be among the machinery utilised to carry out the works, all within a confined operating space of approximately 3,000 sq m.

Commenting on the project, Trevor Nicholson from the BASF Procurement HUB says: : “We sought RVA’s expertise for the Kaipiainen project following their work with us at Seal Sands in the North East of England in 2009, where they demonstrated their ability to meet BASF’s exacting standards when it comes to environmental health and safety. A project of this nature requires a thoughtful, coordinated and attentive approach, plus specialist industry knowledge that we know RVA can deliver.”

Share

RVA supports Maltese energy giant

Enemalta Corporation – the state-owned energy utility giant responsible for generating and providing electricity to the Maltese islands – has begun planning for the future.

Specialist UK-based engineering consultancy RVA Group is currently supporting Enemalta in its review and assessment of two existing power stations – Marsa (MPS) and Delimara (DPS) – as part of the company’s strategy to update their electricity generation technology.

Beginning with the preparation of outline plant decommissioning, this initial phase of work comprises of a monitoring programme and a waste management plan is to be devised as a result.

As MPS is expected to be phased out by 2015, the RVA team must go a step further and develop a full decommissioning plan for this plant with recommendations as to the most suitable de-planting options, associated dismantling and demolition techniques and finally the civil works required to reinstate the site ready for subsequent use. A detailed safety management programme will underpin the entire strategy document.

RVA managing director explains: “As with any decommissioning project there are numerous factors to consider, which is why it is important to undertake extensive investigative work before a recommended plant decommissioning plan is prepared. There can never be a ‘one size fits all’ approach. On this particular project we have to think about the removal and dismantling in the most cost-effective way of all mechanical and electrical equipment and the structures themselves.

“This client is keen to ensure best practice from day one, therefore it is crucial that every risk is assessed and every opportunity explored.”

RVA’s plans – which are to be submitted to the Malta Environment and Planning Authority (MEPA) for approval – will detail how, in what sequence and over what period of time this project should be pursued, together with an estimate of the resources required, security protocols and the costs involved. The authorised, plans will form the basis for decommissioning implementation at the appropriate time.

Martin Attard-Montalto, division manager at Enemalta, commented: “We know we are going to need additional generation capacity in the coming years, but we have recognised the need to replace some of our outdated technology with more efficient plant. This will not only ensure legislative compliance but will significantly reduce primary fuel consumption and subsequent emissions.

“We appointed RVA following a rigorous tendering process, on the basis of their specialist expertise and proven independent experience within the field of planning for power station decommissioning. It is important that Enemalta makes not only the safest, but also the most environmentally and commercially sound decisions going forward, so this guidance and much-needed insight will allow us to progress in this manner.”

RVA has undertaken similar projects in the past – for example asset and liability assessments and baseline decommissioning plans have been carried out previously for both Magnox and British Energy, and the RVA team has recently completed detailed front end engineering support to EDP, for their power plant demolition project in Barreiro, Portugal.

Enemalta’s current power generation technology is expected to be replaced by a new plant at Delimara and by submarine interconnection to the European grid.

Notes:

Marsa power station is an electricity generating plant comprising six fired boilers, six generating turbines (30MW to 60MW), one open-cycle gas turbine, seven fuel storage facilities and four stacks (up to a maximum 75m in height). Almost all electricity produced at Marsa is derived from the combustion of HFO (residual heavy fuel oil).

Delimara power station comprises two fired boilers with two 60MW condensing steam turbines utilising HFO. Elsewhere two 37.5MW open-cycle gas turbines, two 38.5MW gas turbines and one 38MW fully condensing steam turbine (in a combined-cycle arrangement with two heat recovery steam generators) utilise GDO (gas/diesel oil) . There are also four stacks – the tallest of which is 154m in height.

A new plant at Delimara is due for commissioning mid 2012 and will consist of eight diesel engines (with selective catalytic reduction and waste heat recovery boilers), a single condensing steam turbine and four steel stacks.

Share

RVA’s expertise highlighted in industry magazine

The specialist expertise of RVA Group has been highlighted in leading industry publication Process Engineering. In the March – April 2011 issue, RVA considers the evermore challenging arena of process plant decommissioning…

“The difficult economic conditions of recent times have affected widespread processing sectors with quite overwhelming results. Unprecedented pressures have been placed on chemical, petrochemical, pharmaceutical and manufacturing companies across the globe, and very few have proven recession-resistant.

This is not to suggest there will be a permanent exodus of the processing industry, even in the UK alone. However it cannot be ignored that the number of production facilities being mothballed, rationalised or permanently closed down remains staggering. The specialist area of decommissioning may therefore be a great step into the unknown for most organisations, yet it is perhaps equally an inevitability for many.

The challenge is how to deal with the decommissioning – and in many cases decontamination, dismantling and demolition – of facilities safely, whilst at the same time cost-efficiently and with minimal environmental impact.

It should not be expected that the majority of businesses are competent to proceed with such projects without specialist external guidance. Decommissioning is not always a straightforward process and cannot be viewed merely as an extension of normal operations or the reverse of commissioning and construction. Nor should it be rushed in an attempt to achieve an accelerated exit. Decommissioning is an inherently hazardous activity and should be managed by appropriately experienced professionals, and the most important way to ensure a project’s success is getting the team right from the start. A specific set of skills and competencies is required to ensure the management of safety is proficiently catered for, and that the achievement of safety excellence is at the top of the ‘to do’ list.

The careful use of an organisation’s own engineering and production staff is in most cases a positive and value-adding move. Effective decommissioning is underpinned by a thorough preparatory and planning process whereby assets, procedures, decontamination and isolation details are comprehensively documented on an ongoing basis so that everything can be accounted for, and the plant can be brought to the required ‘known state’. No one will know this plant-specific information better than the people that have been running it, so key personnel should be involved from the outset.

However projects of this nature and scale tend to lie beyond most companies’ usual remit, and there will be areas of expertise that cannot possibly be fulfilled in-house – it is not reasonable to expect a skilled production manager for example, to become a qualified decommissioning engineer overnight. Instead the knowledge-based management support of external engineering consultants should be sought, so that any given project and its inherent risk, is competently managed.

By law, all UK demolition projects must be carried out in accordance with Construction Design Management (CDM) regulations. Revised in 2007, the regulations are not just a matter of paperwork compliance. Instead they govern the planning, coordination and management of projects to secure the health, safety and welfare of all involved. A competent and relevantly experienced CDM coordinator must therefore be appointed to oversee the project in this respect, and ensure consistency of standards.

Outside of the UK, whilst the legislative terms and job titles may differ, the principles, roles and responsibilities remain the same – manage safety to the highest achievable standards.

Beyond this there is no such thing as a ‘one size fits all’ approach. Every project has to be assessed on its own merits to ensure that a suitably skilled project team – comprising demolition, explosives, chemical, structural and mechanical engineering experts for example – is assembled for the job.

Because the decommissioning process is frequently brought about due to site closure or corporate rationalisation, it is commonly viewed as an unwelcome event and as a consequence, minimal resources are often allocated to what is an incredibly complex and high-risk activity. This can result in poor environmental, health and safety (EHS) performance, and ultimately commercial failure.

Even with the best intentions at heart, when money is tight some companies will take shortcuts, but the global downturn doesn’t mean that hazards are any less onerous, or that legislation can be flaunted. Safety should always be the number one priority.

Safety plans should be compiled in conjunction with other contractual documentation to ensure a cohesive output that does not conflict with risk management and the goal to achieve EHS excellence. Independent and specialist auditing of sites and methodology further helps to ensure best practice, but operations should be reviewed and revised as site works progress because ‘change of state’ can be rapid.

Organisations will understandably be focused on closing down their factories and plants in the swiftest and most cost-effective manner possible, due to the financial pressures that will no doubt have led to the said situation. However in truth a large majority of clients will not know where to turn next.

A feasibility and option study should provide a clear view as to the true liability, or indeed opportunity, of a decommissioning project. The findings and specialist recommendations given by independent experts with an experienced ‘demolition mindset’, could then provide companies with sufficient data and indeed confidence to pursue an innovative route that they perhaps previously deemed impossible, or may even have been wholly unaware of.

Sometimes dismantling elements of a plant for scrap whilst mothballing remaining structures is the preferable route, whereas in other scenarios complete site clearance proves the safest and optimum financial solution. Not only can direct liabilities such as hazardous material containment, security and maintenance costs, and local authority building rates be removed, but in some instances it is even possible to generate sufficient funds from scrap materials to completely cover the cost of the project.

Clearly not all decommissioning work will be self funding or cash generative, but cost-effective solutions can be devised that will help to mitigate a financially difficult situation. The recession has caused many companies to postpone important dismantling and decommissioning projects, as they simply deem them unaffordable, however they will have be tackled at a later date and in most cases at an increased cost.

The goal should always be to maximise return on assets where possible and indeed safe to do so. However factors such as plant age, former process, recovery cost, testing, market forces and commercial competition will all form part of the decision as to what should and should not be salvaged. In some instances it is efficient to recover individual items of plant for resale, however in other circumstances the dismantling of entire processes for reinstallation elsewhere, is possible.

Most importantly, organisations need an early project cost magnitude indication. This information can then be used to compile sanction grade estimates, funding applications and even determine the programme and extent of a project. Once again, specialist expertise and commercial understanding is invaluable in this respect, as factors such as plant resale value, scrap and credit recovery, market conditions and the possible effect of legislative changes, need to be incorporated alongside the direct project costs. However it is crucial that confidentiality, supply chain independence and trust are assured from the outset, so as to protect the commercial security of those involved.

Overall, making use of external expertise should be seen as a value-adding and team strengthening exercise, rather than a loss of control. Furthermore the sooner a specialist consultancy can get involved, the greater the benefit derived. Because it is the duty of the project management and engineering experts to provide safe, environmentally sound, commercially secure and cost-effective outcomes to project, companies can continue to do what they do best – run their business.

Because increasingly larger and more sophisticated world-scale installations are reaching the end of their life – and because legislation and environmental pressures are becoming evermore stringent – it could be argued that decommissioning is becoming an evermore complex practice.

Yet ever-advancing technology and improved knowledge does mean that project solutions are increasingly innovative, cost-effective and safe. The use of explosives for example is now much more precise, and specifically designed equipment is now commonly used to access hazardous areas where previously operatives may have been unavoidably placed at risk.

With an almost bizarre twist, preparing plant and machinery for dismantling and demolition can be less onerous than actually operating it throughout its life cycle, so long as the company has adequately planned for the situation and the best team is assembled for the job.”

To view the full article in print, visit http://digital.centaur.co.uk/processengineering/pe_032011/

 

Share

Maximisation of income for INEOS

Seeking the advice of a specialist engineering consultancy can reveal previously unconsidered opportunities and considerable cost benefits, as INEOS ChlorVinyls has found after appointing RVA Group to manage large-scale UK decommissioning projects in Barry and Runcorn.

INEOS ChlorVinyls – Europe’s largest polyvinyl chloride (PVC) manufacturer – engaged sector-specific CDM coordinators and project managers RVA Group, to oversee the safe execution of these two major projects and ensure the maximisation of income from the resale of redundant plant and metallic arisings including high-value exotic alloys.

RVA commenced its role at INEOS ChlorVinyls’ Barry site after manufacturing ceased in March 2010 as part of a consolidation of activities. Having planned to decommission and clean the site before handing it back to the landlord with the plant intact, INEOS sought RVA’s isolation and decommissioning guidance. However acknowledging the financial implications of INEOS’ proposed site exit strategy, RVA conducted a series of in-depth feasibility and option studies to investigate more commercially attractive routes for the client.

Utilising its vast knowledge and experience of asset recovery, RVA recommended that INEOS hand the site back as flat slab, as plant demolition and dismantling could generate an income from the sale of the process equipment – some had potential for reuse whereas other items (as a result of their high-value metallurgy) would create a positive income stream.

To demonstrate their confidence in the proposed alternative site exit strategy, RVA agreed to work for six weeks – at risk – to test the feasibility of their solution. If the project plan had proven unachievable, RVA would have waived all costs for work undertaken during this investigatory period.

However, as RVA had anticipated, the team was able to demonstrate that the project could be delivered with significant cost savings thus reducing the financial burden for INEOS.

Now RVA is project managing the dismantling and demolition of INEOS ChlorVinyls’ production facilities including process vessels, aluminium and concrete storage silos, a boilerhouse and three steel 1,500 cubic metre storage spheres. With a 27-man team on site, and kit ranging from excavators with shears and grab buckets to an ultra long reach machine safety remains the number one priority.

Colin Hopwood, INEOS ChlorVinyls’ site services manager for Runcorn explains the reason for RVA’s extensive involvement in the Barry site project: “RVA’s role with INEOS in fact commenced with the team’s development of a detailed redundant asset management review for our Runcorn site.

“The Company drew upon its technical engineering experience to assess a number of plants, projected costs of removal, optimised sequencing and a potential rolling decommissioning programme for several areas of the 125-hectare top-tier COMAH site. The quality and integrity of this guidance not only led to us proceeding with the Runcorn works, but I also then recommended their services to a colleague heading up the Barry project.”

Since the sequential decommissioning and demolition of five redundant chemical processing plants began on the high-hazard Runcorn site in August 2010, the site has remained operational elsewhere. Meticulous planning and project coordination has therefore been essential to ensure minimal disruption and utmost safety for all parties.

Priority was given to the complex dismantling of INEOS’ four distillation columns, ranging from 40 to 60 metres in height, which had to be dismantled to a low height before the arrival of the year’s high winds. However due to their proximity to high-hazard pipelines, and given the inherently dangerous nature of hot-cutting techniques, an alternative dismantling process had to be devised. Instead RVA oversaw the more time-intensive, but far safer alternative, of using high pressure abrasive water jets that ran around the circumference of the columns’ cut lines to eliminate the flammable risks, before the top sections could be removed with a lifting nail attached to a 500t crane.

With six months of the programme still to complete, RVA is currently planning for the dismantling of INEOS’ anhydrous caustic soda plant – a procedure that will take place in May 2011. Although the asset is no longer needed by INEOS, the plant is in good condition and is being carefully dismantled for re-erection elsewhere.

Colin Hopwood continues: “Due for completion in August 2011, the clearance of the redundant assets within our Per-Tri, Per-Tri Shipping, ACS, VDC4 and KOH plants will prepare the site for potential new INEOS ventures.

“RVA’s experience supported by impressive client references and commitment to offering independent, value-adding support, cemented our decision to choose their team.”

RVA managing director Richard Vann concludes: “The scenario that we’ve seen at the two INEOS sites is one that is becoming increasingly common. Companies around the world are under great pressure to ensure that their sites are decommissioned safely, but at the same time cost-effectively. This financially challenging and inherently hazardous situation usually represents a step into the unknown for most site owners and operators, which is why specialist engineering expertise and experience is required. Our goal is always to maximise our clients’ return on assets where possible and safe to do so.”

Share

Global demand for RVA’s expertise soars

RVA Group – the UK’s leading expert in large-scale decommissioning, decontamination, dismantling and demolition project management – is preparing for a period of controlled growth in 2011 following a record-breaking 12 months’ performance.

The company, which has enjoyed year-on-year expansion since its formation in 1992, saw turnover increase by 15% from 2009 to 2010. Much of the new work is being driven by RVA’s growing international presence, with organisations from around the world turning to the Ipswich-based company for help when decommissioning major industrial processing sites.

RVA’s managing director Richard Vann explains: “Many large, complex, high-hazard installations worldwide are now reaching their end of life. This challenging area of work remains inherently high-risk so the need for our specialist engineering support in the UK and overseas is paramount.”

Having now completed in excess of 500 projects – including some of the largest process plant decommissioning assignments this country has ever seen and in locations as challenging as Turkmenistan – RVA has worked with many internationally renowned blue-chip organisations such as GlaxoSmithKline, BASF, Ineos, GrowHow, CIBA and ConocoPhillips to name a few.

In 2010 RVA’s expertise was called upon to provide project management assistance and technical guidance for a 7-hectare Portuguese power plant decommissioning project. In January the team was appointed to provide specialist demolition and safety expertise to support the clearance of a cement works in Cyprus, and now – as its overseas reputation continues to grow – RVA is receiving further enquiries from countries across Europe, including the Netherlands, France and Germany.

The website has been a key driving force in attracting global interest in recent months. With a multi-lingual homepage that can be translated into seven different languages, the site is designed to be an informative resource from which prospective clients can make informed, considered decisions about what steps to take when facing site rationalisation or closure.

Whilst RVA is looking forward to taking on new international projects, the expansion will be steady and controlled in order to maintain the company’s exemplary EHS (environment, health and safety) record. RVA will also remain committed to providing an independent, tailored service with bespoke recommendations for every client, taking into account each project’s unique factors and requirements.

To support the projected growth, two new specialist project managers have been recruited to join the company’s existing team of engineering experts, with further expansion of RVA’s skill-set planned for this year.

“RVA has become well established as a UK market leader in the technically challenging field of decommissioning consultancy services, and we anticipate that projects within this country will remain integral to our business model going forward. However with the increased number of large-scale industrial site closures occurring across the globe, we are now ready to achieve our long-term strategy to become a market leader on the international stage too,” concludes Vann.

Share

Authoritative role for RVA at leading event

The specialist expertise of RVA Group has been sought by the Institution of Mechanical Engineers (IMechE), as part of an authoritative one day seminar focusing upon redundant plant.

Set to attract site owners and operators from throughout the country, the Wilton event will offer an in-depth look at the engineering and safety issues typically faced when managing redundant assets. A programme of presentations is planned for the 19th May 2011, with RVA delivering a session focusing upon “Dismantling Plant for Sale and Re-use” at 14:05.

Having completed in excess of 500 large-scale, complex and high hazard projects, RVA can offer much-needed expert guidance regarding what is usually a step into the unknown for many organisations.

An RVA director explained: “Companies across the globe face great uncertainty when assessing the viable options for redundant plant. However, day in day out, RVA works exclusively for clients within these financially challenging and inherently high-risk circumstances, to provide a much-needed professional insight into this very specialist area of engineering.

“We therefore have a lot to offer at a leading industry event such as this. Since 1992 our team has been dedicated to providing unbiased, uncompromised, knowledge-based management support – in the disciplines of decommissioning, decontamination, dismantling and demolition – so I would encourage anyone who is currently (or potentially) facing site rationalisation or closure, to attend.”

RVA’s presentation will investigate:

  • What feasible options exist for redundant plant?
  • How to establish the commercial viability of dismantling plant for sale and re-use before approaching the market?
  • How to ensure vendor control over the project execution and finances?
  • What methodology and subsequent management approach will ensure facilities are decommissioned, isolated, demolished and/or dismantled safely, whilst at the same time cost-effectively and with minimal environmental impact?
  • What potential challenges and risks are associated with this complex activity and how these can be identified, anticipated and overcome?

For further information about the event, contact RVA or visit the IMechE website.

Share

Cementing Overseas Relationships

Working with local consulting engineers PPA, RVA is developing the demolition and site clearance plan for the Moni cement works owned by Cyprus Cement Public Company, a member of the Galatariotis Group.

Share

EU Win In Energy Sector

One of Europe’s major energy operators Energias De Portugal (EDP), has appointed RVA to provide project management assistance and technical advice during their vast demolition and site clearance project in Portugal.

As the UK’s leading expert of large scale decommissioning, decontamination, dismantling and demolition projects, RVA is supporting EDP throughout the decommissioning and demolition of its 7 hectare power plant in Barreiro, Portugal.

RVA has already helped EDP prepare a detailed project specification and tender documentation, and will play a key role in the contractor selection programme. Following the appointment of a contractor, RVA is available to continue to work with EDP, providing specialist project management support and technical advise as required throughout the programme of works.

The project will include the demolition of several large structures comprising a 1,000m oil and steam pipeline, engine room, boiler, steam turbines, pumping station and two on-site reservoir tanks, each measuring 7,500m³.

Share