Optimation’s client experienced an explosion, destroying a building and the process within. Although well-contained and with no personnel injured, it was imperative that the building and process be rebuilt as quickly as possible so production could resume. Optimation had a total of six months to assess, plan, design and rebuild.


Optimation designed the new building and worked with the client and a building construction firm. Optimation designed and released the new process equipment, as well as the new utilities. For quality and efficiency, Optimation was chosen to do both the mechanical and electrical work, including utilities, switchgear, motor control centers, and all the process equipment procurement and installation. Procuring components was a major challenge, due to lead times for explosion-proof components. Several areas of the building were classified C1D1, which dictated that special components be used. The goal was to replace the equipment in kind, although some had to be redesigned due to age and advances in technology. Skids were designed and built for the process equipment to expedite installation and reduce downtime. A large pipe rack was designed and built in Optimation’s shop in sections and painted. The sections were moved to the site, hoisted onto the roof, and welded together. This made for a very efficient process and saved installation time in the field. Block walls were reinforced per code, and the roof of the building was supported by building steel.


At this point the client is completing commissioning for resumption of production. Structural fixes will prevent future building and process incidents. The team went from a pile of rubble to commissioning work in six months.