Blowdown Pipeline — FRP Detail Engineering, Ras Al Khair

The challenge

Client needed a buildable design for a new cooling-tower blowdown water discharge line at its Ras Al Khair plant in Saudi Arabia: 1,600 metres of FRP piping at 12 bar, crossing roads underground and joining an existing 3D pipeline route — with civil foundations, supports and metering all designed as one package.

Our scope

• Pipe sizing for a 12 bar discharge pressure
• Material selection and specification for the FRP piping system, fittings and valves
• General arrangement and underground road-crossing drawings
• Sleeper stability and foundation calculations, sleeper layout and foundation drawings
• Sampling point and flow meter arrangement near the pump discharge
• Integration of the new route with the existing 3D pipeline route
• Bill of quantities for piping, supports and civil works

Our approach

Piping, process, stress and civil engineers worked on a single model and drawing set, so pipe sizing, support spacing and sleeper foundations stayed consistent along the whole route. The FRP system was specified to ASTM D2996 / D3517 and analysed in CAESAR II, and all drawings followed Client’s documentation standards in MicroStation and PDF.

• Pipe size calculation and report for the design pressure
• Sleeper stability and foundation design checked against site data
• Underground road crossings detailed with method and protection
• New route integrated with the existing 3D pipeline model

The outcome

The project was awarded and completed. Client received the pipe size calculation report, piping layout and route drawings with flow meter and sampling point details, pipe support and RCC sleeper footing drawings, underground road-crossing design, BOQ and the 3D model — a complete package ready for procurement and construction.