Our experts and engineers have been challenging and refining our process for decades, giving Enerquip a reputation for innovative design, efficient manufacturing, excellent quality, and outstanding customer service.
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. Our approach ensures frequent communication throughout the design, fabrication and testing of your equipment. From engineering through delivery, you can count on a streamlined process.
Enerquip’s Proven Project Management Process
(1) Milestone Schedules
Depending on the complexity, size, and quantity of pieces in your order, we may develop a detailed milestone schedule for the design, procurement, machining, fabrication and testing of your equipment. For each step, this will provide you with a start and finish date, along with a planned ship date.
Enerquip has an outstanding track record of meeting or beating our planned ship dates. To support this, our management team meets weekly 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 bi-weekly through final inspections. If you’d like, clients are welcome to witness the final step before shipment – hydro-tests.
(2) Design Process
During the kick-off meeting, equipment 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 pieces purchased, the designers should have drawings ready in about 5-7 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.
(3) SOURCING PLAN
Once drawings are approved, our Design Engineers issue a final bill of materials to purchasing so materials can be ordered. We have a reliable and high-quality network of suppliers for all raw materials and any outsourcing required.
To be mindful of lead-times, our equipment is designed with as many common components as possible. If there are longer lead-time items like expansion joints, flanged and dished heads or special higher alloys, you will be notified of this during the quoting stage. These items will be noted on your milestone schedule.
(4) QUALITY PLAN
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 Quality Control Manager, as well as a 3rd party inspector from Hartford Boiler. Quality Control will develop the Factory Acceptance Test (FAT) for the equipment, if needed, and submit for review. Quality Control will coordinate visits for customer inspections – which we welcome.
(5) FABRICATION PLAN
Considering today’s elevated material lead-times, along with our machining, welding and fabrication hours, your equipment is then scheduled into production. Time in production will vary depending on the equipment purchased. For select off-the-shelf equipment, it could be next day. For large systems, lead times may be over twenty weeks. Talk with your Sales Engineer for specifics on your equipment.
(6) Factory Acceptance Test
When required, Quality Control will develop an ITP (Inspection & Test Plan) for the equipment.
For example, because 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.
(7) SAT / START-UP SUPPORT
We provide general installation instructions for all our equipment in their documentation turnover package.
Enerquip is in the business of designing and fabricating quality thermal solutions, however we do not have the equipment, licenses, or experience to install process equipment at customers locations. For this reason, and the fact that much of our equipment is being installed into even larger systems, 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.
(8) OPTIONAL CLEANING / PACKAGING PLAN
If our customers anticipate storing their equipment for an extended period before putting them into service, we can passivate and/or nitrogen charge the equipment, 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.
(9) SHIPPING PLAN
Our equipment will have all of its openings sealed and then be palletized and bolted down for shipment. They will be 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 equipment 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.
(10) DOCUMENTATION TURNOVER PACKAGE
All project documentation will be organized to be previewed at the time of Factory Acceptance Testing. 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.
Project management at its finest
Seamless tube inspection
Quality welds and inspection
Liquid penetrant testing