Because Enerquip works with highly professional engineering firms, and the top companies in the industries that we serve, we have adopted a detailed approach to project management. This ensures frequent communication throughout the design, fabrication and testing of your heat exchanger, preventing roadblocks and streamlining the entire process, from engineering through delivery.
Enerquip’s Proven Project Management Process
Depending on the complexity and number of heat exchangers you purchase, we may develop a detailed milestone schedule for the design, procurement, machining, fabrication and testing of your equipment. This will show you the start and completion dates for each step, with a planned ship date. Enerquip has an outstanding 40-year track record of meeting or beating our planned ship dates. To support this, our management team meets every Tuesday morning to review the status of higher profile projects, to review completion status, obstacles, expediting options (if needed), and pending action items. Once equipment is in fabrication, progress reports with photos can be provided every other Friday until hydro-testing is scheduled – and the client is welcome to witness hydro-tests.
During the kick-off meeting, exchanger data sheets are reviewed and fine-tuned to ensure that the thermal designs that were developed, also comply with ASME and seismic codes. Design Engineers will then run ASME Code and seismic code calculations using Compress software, to confirm material thicknesses. Next we complete general arrangement drawings for submittal for customer approval. Depending on the number of exchangers purchased, the designers should have drawings ready in about 3 – 5 business days. If full calculation and detailed drawings are needed for the approval process, allow a couple more weeks for the submittal process. Once drawings have been submitted, we encourage a design review web meeting to confirm nozzle locations and support locations. Once you return your approved drawings, we can begin purchasing materials and scheduling production.
Once drawings are approved, the Design Engineers issue a final bill of materials to purchasing so materials can be ordered. Most exchangers are designed with as many common components as possible, so most materials are either in stock or can be in-house within 2 weeks. If there are long lead-time items like expansion joints, flanged and dished heads or special higher alloys, you will be notified of this during the quoting stage, and these will be noted on your milestone schedule. We have a reliable and high quality network of suppliers for all raw materials and any outsourcing required.
We create shop travelers for fabrication per our Quality Manual, in accordance with ASME Section VIII, Division 1. This plan also has detailed procedures for purchasing and receiving materials, maintaining material traceability, weld procedures, welder qualifications, inspection steps and hydro-testing protocols. All drawings, travelers, materials, weld procedures and inspection plans for the equipment are overseen by our QC manager, as well as a 3rd party inspector from Hartford Boiler. QC will develop the FAT plan for the exchangers, if needed, and submit it for review. QC will coordinate visits for customer inspections – which we welcome.
Heat exchangers are scheduled into production, accounting for material lead-times, and allowing for any machining, welding and fabrication hours needed. Materials typically take 2 weeks to arrive, and most exchangers are in fabrication for 4 – 5 weeks from start to finish.
When required, QC will develop an ITP (Inspection & Test Plan) for the equipment. Since shell and tube heat exchangers have no moving parts, the FAT is typically an inspection of physical dimensions, nozzle locations, and support locations as a mechanical comparison against the drawings, specifications and data sheets. We review documentation for completeness and accuracy. Any special process involved in supplying the exchangers, like electro-polishing or passivation of the tube side surfaces, will also be reviewed. Hydro-testing of both the shell side and tube side of the exchangers is witnessed by our 3rd party Hartford inspector, and can also be witnessed by the customer.
SAT / START-UP SUPPORT
Since shell and tube heat exchangers are fairly simple pieces of equipment with no moving parts, installation is fairly straightforward. We do provide general installation instructions for the exchangers in our documentation turnover package. Since Enerquip is only in the business of designing and fabricating equipment, we are not equipped to install heat exchangers at client sites. We do not have the equipment, licenses or experience to install process equipment. For this reason, and the fact that we do not design the systems that the exchangers are installed into, we do not typically engage in start-up and commissioning activities. We can provide thermal design support and customer service support by phone, email, or web conference at no charge to our customers.
OPTIONAL CLEANING / PACKAGING PLAN
If our customers anticipate storing their exchangers for a time before putting them into service, we can passivate and/or nitrogen charge the exchangers, for an extra cost. Exchangers are rinsed out, and passivated with hot citric acid solution to clean and degrease the product contact surfaces. This also passivates the stainless to provide additional corrosion prevention. A final rinse with DI water flushes out any residual citric solution. The exchangers can also then be charged with nitrogen under low pressure, with fittings capped for shipment.
Exchangers will have all openings sealed and then be palletized and bolted down for shipment. They are reinforced with banding straps and shrink wrapped for truck transport. Larger units are bolted to blocking to load directly on the truck. We enclose any spare parts in a wooden crate with the parts labeled. Transit time within the lower 48 states is approximately 3 days, and palletized exchangers can be offloaded with forklifts or cranes. International shipments can be crated with treated wood per ISPM-15, ready for ocean or air freight to anywhere in the world.
DOCUMENTATION TURNOVER PACKAGE
All project documentation will be organized to be previewed at the time of FAT. Most of the documentation is hard-copy at that time. Once hydro-testing is completed, and final documents are available from our third party Hartford inspector, all documentation is scanned and catalogued. This can then be sent by FTP site to the client’s documentation department. This is usually ready within 1 – 2 weeks of equipment shipment.
A Look Inside Our Project Management
611 North Road, Medford, WI 54451
PO Box 467, Medford, WI 54451