NFPS EPCO Project, notable for its achievement of coating the largest pipe ever with an injection mold in Shawcor’s global plant history.
🔹 Background & Engineering Challenges
The NFPS EPCO Project presented a unique engineering challenge, requiring modifications and enhancements in multiple areas to handle an unprecedented pipe size. Key objectives included:
✔ Structural and mechanical adjustments to existing systems for large-diameter pipe handling.
✔ Capacity assessment and process optimization to ensure safe and efficient execution.
✔ Development of new handling procedures to minimize risk and improve efficiency.
✔ Compliance with safety and engineering standards while executing the modifications.
🔹 Engineering Modifications & Process Development
1️⃣ Equipment & Infrastructure Adaptation
🔧 Structural Reinforcements – Evaluated and reinforced existing machinery to withstand increased load capacity.
📐 Handling System Upgrades – Designed and implemented modifications to conveyor systems, rollers, and support structures.
🏗 Lifting & Transport Adjustments – Upgraded lifting and rotation mechanisms to ensure smooth handling of the large-diameter pipe.
2️⃣ Process Optimization & Workflow Management
📊 Workflow Redesign – Developed an optimized process sequence to integrate the new pipe dimensions.
⚙ Cycle Time Adjustment – Conducted time-motion studies to adjust production schedules accordingly.
🔍 Risk Mitigation Strategies – Identified potential failure points and implemented preventive engineering solutions.
3️⃣ Structural Analysis & Mechanical Validation
🛠 Finite Element Analysis (FEA) – Assessed stress distribution and load impact on handling equipment.
🔬 Mechanical Integrity Testing – Verified the stability and performance of modified support structures.
📏 Precision Calibration – Ensured dimensional accuracy and alignment in all modifications.
🔹 Operational Impact & Project Execution
🚀 Enhanced Handling Capacity – Enabled processing of larger and heavier pipes without compromising efficiency.
🏭 Improved Safety Measures – Implemented engineered controls to prevent structural overloading and minimize risks.
💡 Future Scalability – Established a framework for handling larger pipes in future projects.
🔹 Conclusion
The NFPS EPCO Project marked a groundbreaking advancement in Shawcor’s engineering capabilities. Through strategic modifications, process optimizations, and infrastructure reinforcements, the project successfully accommodated the largest pipe ever handled, reinforcing Shawcor’s position as a leader in advanced pipeline engineering solutions.