New CO₂ Recovery Plant — Hydraulic, Process & Piping Detail Engineering

The challenge

New CO₂ recovery plant is fed by a single 2,500-metre pipeline from the existing CO₂ absorption plant. The line size had to be confirmed for two design flow rates, the route had to cross a road and tie in to live facilities, and the existing pipe rack carrying part of the route had to be proven adequate — all before construction drawings could be issued.

Our scope

• Hydraulic analysis of pressure drop for both flow rates across 12", 14", 16" and 18" pipe sizes to select the line size
• Process & piping detail engineering for the full 2,500 m route
• Stress analysis of the entire pipeline
• Road-crossing pipe bridge design and existing pipe-rack stability check
• Structural details with sizing calculations and sleeper support design
• Tie-in isometrics for the raw CO₂ line and demolition GA/isometrics
• Engineering support for field modifications

Our approach

Our Chennai engineering team started with the hydraulics, comparing pressure drop across four candidate line sizes so the pipe size was fixed on evidence before any routing began. Piping, stress and structural engineers then developed the route together, working to Client’s codes, FEED datasheets and piping material specifications.

• Line size selected from a four-size hydraulic comparison
• Stress analysis run on the complete pipeline, including the road crossing and pipe-rack sections
• Pipe bridge and existing pipe-rack checks carried out alongside piping design
• Structured review cycles with the client before each issue

The outcome

The project was awarded and completed. Client received a full construction package — hydraulic analysis report, construction P&ID and datasheets, tie-in isometrics, stress analysis report, construction GA drawings, isometrics, detailed pipe support drawings and piping bulk MTO — with field-modification support available during construction.