Bayer CropScience Multiple Train Liquid Formulation Plant

This project involved the strategic conversion of the Owner’s existing dry flowable formulation facility to a liquid based formulation facility. The project consisted of demolition to remove piping, equipment and structural steel floors from a four- story plant. Rand rebuilt the interior structure of the plant to accommodate the different types of equipment needed to operate as a liquid formulation unit. Rand installed new foundations, structural steel, flooring, pipe racks, equipment, process and utility piping, HVAC and process vent systems. In addition, Rand installed all instrumentation pneumatics necessary to support the plant conversion. The installation project consisted of setting approximately 145 major equipment items and the fabrication and erection of 251 piping lines. Rand's scope included the installation of agitators in the vessels, as well as the installation of all in-line and on-line instrumentation. The scope of the instrumentation pneumatics included all work from the installation of the multi-tube bundles to the individual instrumentation connections.

During the course of the project, the Owner awarded additional work to Rand, including a tank farm and two truck and seatainer loading and unloading facilities. Rand also provided commissioning support during start-up.

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Although the project was not a full design/build effort, it included the development of all piping isometric drawings and fabrication details from limited piping plans and sections. The logistics of the project were very challenging, due to the close coordination of the equipment and structural steel required to facilitate installation of the large equipment items. In addition, the construction schedule and plan required continuous adjustments to accommodate the changing delivery forecast of existing equipment relocated from other Owner sites.