MINI-CASE STUDY 02 | PIPING SHOP FABRICATION | EAST CHICAGO, IN
Market: Oil & Gas
Location: Channahon, IL
Scheduled Timeframe: Four weeks
As part of the upgrade of a heater used for its coker unit, an Illinois-based oil and gas refinery needed to replace a large amount of deteriorating piping. Thanks to a long-standing partnership, the client once again tabbed Manhattan Mechanical Services to efficiently and effectively prefabricate 7,700 linear feet of heater tubes with return bends within a comparatively short timeframe. The results were a safe project, minimal downtime, increased quality and, ultimately, substantial cost-savings.
For this project, 7,700 linear feet of heat tubes, ranging from 3” and 4” in diameter, were fabricated at Manhattan Mechanical’s East Chicago, IN, facility to tolerances of 1/16 of an inch. The pipes were 100% X-ray-inspected for weld defects.
- Oversized loads
Permitting was required to move the 70-foot lengths of heater tubes to the client’s refinery. Manhattan Mechanical handled all aspects of this transport, including logistics equipment rental, the permitting required in multiple states, and driving the trucks.
- Exceptional project coordination and multi-skilled craftsmen enable quick turnaround time.
Such a large pipe fabrication project demands finding the most efficient and effective way to deliver the product within a short time frame. The challenge lies in optimizing available space, planning when loads will be received and the timing of setting out the material, NDE (coordinating with subcontractors), and maintaining the capacity to work efficiently.
Thanks to the optimal organization and planning skills of Manhattan Mechanical’s multi-crafted professionals, all 7,700 linear feet arrived at the refinery a week ahead of the client’s schedule. As a result, the client saved a considerable amount on overall project costs.
Manhattan Mechanical provides partners with highly-skilled, multi-crafted craftsmen that enable the customer to increase their margin of profit. These craftsmen are pipefitters, boilermakers, insulators, carpenters, millwrights, ironworkers, scaffold builders, etc.
During this particular shop job, the same group of craftsmen handled welding, pipefitting, material handling, etc., leading to increased efficiency and a shortened turnaround time.
- Carbon Steel, Stainless Steel, Chrome Moly, Duplex Stainless, Nickel,
Inconel, Monel, Hastelloy
- 3/4” to 30”
- .1875” to 8” .125 to schedule 160
NBIC “R” Stamp
- B31.3 and API 1104
- 5/32” gap +- 1/8”
In Process Testing/Inspection Performed:
- 100% X-ray and final PT
- Confined Space Permit, Hot Work Permit, 4 Gas Meter, O2 meter in the furnace near each welder, Harness Required and a half mask for entry and welding.
- JSA’s analysis, tool-box talk, two weekly safety audits
- Overhead crane loading/rigging,
- Pipe beveling
- Layout for NDE
- Coordination between subcontractors, logistics, warehouse management, crew and client; rental of logistics equipment to transport, permitting required in multiple states to transport oversized load.