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Rockford Engineering Works Regina Saskatchewan Canada Piping & Process Design Trans

Natural Gas Process and Piping Design

A local client had a requirement to build a number of remote natural gas compression sites in a short period of time. They contacted Rockford Engineering to take existing designs, modularize them, and make them expandable to meet local compression demands. The client’s desire was for the design to focus on as much in-shop fabrication and assembly as possible in order to minimize installation time in the field.
Rockford Engineering Works Regina Saskatchewan Canada Piping & Process Design Trans

Our Solution

We worked closely alongside our client to design the compressor station while ensuring compliance with all applicable codes and regulations. Using a combination of Cadworx for the piping models, and Autodesk Inventor for all other mechanical items, Rockford delivered a successful project.

A set of fabrication and instrumentation drawings were completed to ensure every assembly was plumbed in the same manner before arriving on-site. Using the 3D piping model, Rockford created spool drawings with special consideration for the tie-in connections in the field – these were then issued to the pipe fabrication shops. Rockford Engineering Works Regina Saskatchewan Canada Piping & Process Design Trans Rockford Engineering Works Regina Saskatchewan Canada Piping & Process Design Trans

All piping skids were designed to be modular and accommodate any number of additional interconnected skids, which could be easily dropped onto existing pile caps and welded in place. In addition, the existing facility condition was surveyed to ensure a seamless fit with the items being expanded.

Rockford designed the piping to meet the requirements of either ASME B31.3 or CSA Z662 (whichever was applicable), ensuring that all pipe was completely inspected, x-rayed, and hydrostatically tested. Because the design allowed for the majority of this work to happen in-shop, our client realized substantial cost savings on this project.

The skids were also designed to have modular platforms, grating, handrails, and guardrails compliant with the requirements laid out by the National Building Code of Canada and Occupational Health and Safety. Platforms were designed to interconnect between the compressor buildings to allow the operators and maintenance personnel to walk along safely and access all valves and instrumentation air with ease.

Rockford prepared the layout for the cable tray runs and designed appropriate support stands. Expansion joints were specified to account for thermal expansion, and the cable tray was fully detailed with part numbers, cut lengths and assembly hardware. Similar to the skids and piping, the cable tray supports were designed to be fully fabricated in-shop and shipped to site for installation on piles – a design which included a threaded rod levelling connection at the base for ease of installation.

Previously, instrumentation was run in the field with the aid of only a Process and Instrumentation Diagram (P&ID); causing issues for our client such as plumbing being installed incorrectly, and necessary parts being missed altogether during procurement. These issues were further compounded by installations taking place in remote locations, so acquiring new fittings or parts short notice was problematic. To alleviate this, all valves, actuators, regulators, fittings, tubing, etc. were modelled by Rockford and represented in a 3D layout using Autodesk Inventor. This was further supported by a complete set of instrumentation assembly and installation drawings, which also conformed to ASME B31.3 or CSA Z662 as applicable.Rockford Engineering Works Regina Saskatchewan Canada Piping & Process Design Trans


Work with Rockford

Rockford Engineering has specific expertise in mechanical piping design, along with all required equipment supports, electrical tray supports, platforms, walkways, and guarding. Our engineers’ combination of knowledge of the pertinent codes and regulations, along with industry-standard manufacturing and installation processes, makes us a perfect candidate for projects of this nature.

Whether designing a new system for your specific application or modifying an existing system, Rockford can help.

We cater to all industries in both mobile and plant environments – contact us today!

Spiral Pipe Double Jointing Facility

Improving a Spiral Pipe Double Joining Facility

In 2015, a local large-diameter steel pipe producer contracted Rockford Engineering to assist them with the design and implementation of a new Double-Joining facility. Double-Joining is a process where spiral pipe offcuts are re-cut, bevelled, welded together, and inspected to form a saleable full-length product. Their current system did not have the capability to process the larger diameter and heavier wall product that would be produced.

The client elected to re-purpose an existing building on their current site that would house a combination of used equipment (purchased by the client), re-purposed equipment from their existing process, and new designs. Rockford’s scope of work was as follows:

  • Evaluate and survey the existing buildings to determine available space, yard machine travel paths, crane way envelopes, and overall product flow.
  • Evaluate and catalogue purchased equipment using existing drawings and felid sketching. Equipment such as conveyors, lifts/letdowns, skids, and indexers were obtained by the client from a decommissioned facility elsewhere.
  • Analyze existing client process equipment to determine what could be used in the new layout. This included sorting through archive drawings and field sketching certain areas during periodic maintenance shutdowns.
  • Design and prepare drawings for all new process and handling equipment that would be required to complement the purchased and existing equipment.

Spiral Pipe Double Joining Facility

Our Solution

Purchased equipment was offloaded and staged at the client’s yard. Rockford field sketched and cross-referenced the existing drawings to ensure no discrepancies existed. All equipment was 3D modelled in Autodesk Inventor and was reviewed for both fit and function to determine what would or would not work in the new layout. An in-depth understanding of pipe handling and how different types of process equipment needed to fit together to work properly was key in determining what was practical and usable.Spiral Pipe Double Joining Facility Rockford’s focus during the sketching of the client’s existing process equipment was on takeover points, operational envelope, and capacity limitations. A fundamental understanding of how pipe is bevelled, welded, handled, and inspected was crucial in evaluating the viable relocation of the client’s existing equipment. A costs benefit analysis was performed to determine if it was commercially profitable to relocate and repurpose the equipment, or to make new. Our experience in the tube and pipe industry allowed us to prepare high-level cost estimates regarding design, fabrication, and installation in order for the client to make informed and timely decisions.pipe process and handling rockford engineering saskatchewan

Rockford was also tasked with performing a detailed cycle time analysis for the facility. Both new and existing hydraulic power units were to be considered and a completely new circuit design was required for the new layout. This included P&ID’s, line sizing, valve selection, and pipe transfer time estimates.pipe process and handling rockford engineering saskatchewan Spiral Pipe Double Joining Facility

All equipment was pulled together in one master 3D model and presented to the client for feedback. A number of tweaks and iterations took place to ensure all client’s internal departments were satisfied with the product flow, area access, and safety (engineering, operations, maintenance).Spiral Pipe Double Joining Facility

All fabrication and installation were awarded to a local shop that Rockford often works closely with. We were able to work easily with them to ensure all designs were completed to spec. and that all equipment was installed as intended.

pipe process and handling rockford engineering saskatchewan Spiral Pipe Double Joining Facilitypipe process and handling rockford engineering saskatchewan Spiral Pipe Double Joining Facility


Work with Rockford

Rockford Engineering has specific expertise regarding mechanical and automation design in the pipe handling industry. Our engineers’ combination of both practical in-the-field experience and technical training makes us a perfect candidate for projects such as this.

Our in-depth understanding of how pipe is made and processed can be an asset in both greenfield and brownfield initiatives. Whether designing a new system for your specific application or analyzing an existing system for improvement and optimization, Rockford can help.

We cater to all industries in both mobile and plant environments – contact us today!

pipe handling automation processing

Pipe Handling & Inspection Automation

The team at Rockford Engineering brings knowledge and enthusiasm to every project, but local projects ramp up the enthusiasm which helps to deliver world-class solutions to our local industries. In 2013, we were given the opportunity to design and fabricate an automated pipe-handling facility in the heart of oil country Saskatchewan, Estevan. After the successful startup up and implementation, a second system was provided to CJ’s Grad Prairie facility in 2017.

Clayton Jahn, the owner of CJ-CSM Inspection Ltd. was worried about the implications of human error in regards to their pipe handling including safety concerns for workers and leaks once the product went into the field. He decided to reach out to Rockford Engineering Works Ltd. to see if it was possible to create an automated system that would increase efficiency, be more reliable, and offer employees a safer work environment. The result was an automated pipe handling and inspection facility.Pipe Handling & Inspection Facility Saskatchewan Rockford Engineering Pipe Handling & Inspection Facility Saskatchewan Rockford Engineering Pipe Handling & Inspection Facility Saskatchewan Rockford Engineering

From the initial napkin sketch, through fabrication, testing, and installation, Rockford worked together with CJ-CSM to help create a safer, more efficient facility, with all of the facility’s sorting and cataloguing of pipe being performed by one operator safely behind a touch screen monitor.

Pipe Handling & Inspection Facility Saskatchewan Rockford EngineeringPipe Handling & Inspection Facility Saskatchewan Rockford Engineering

Key Features of the Facility

Rockford Engineering Works Ltd. Portfolio Regina

  • The facility is operated through a programmable logic control system (PLC)
  • From a touch screen station, the automated inspections allow the facility to sort and catalogue all pipe into appropriate batches
  • Five building exits allow for sorting and storage of pipe for future processing
  • All equipment was designed to be modular for quick installation and easy replacement of wear items such as v-rolls and transfer blades.
  • The system was pre-wired and completely shop-tested with the actual product prior to shipping.
  • Installation and start-up of the system was fully supported on-site by Rockford engineers and technical resources.

Pipe Handling & Inspection Facility Saskatchewan Rockford Engineering Pipe Handling & Inspection Facility Saskatchewan Rockford Engineering Pipe Handling & Inspection Facility Saskatchewan Rockford Engineering Pipe Handling & Inspection Facility Saskatchewan Rockford Engineering

See All the Project Images

 

Rockford continued to stay in touch with the client not only to ensure the system operated properly but to receive feedback for further improvements. We take pride in working with our clients and believe this is an important part of our process.

“By working with a local engineering firm here in Saskatchewan, we benefitted from the drive and teamwork to do something totally different and many times better.”

– Clayton Jahn (SIMSA, Chain Reaction: A Series of Case Studies on Saskatchewan’s Industrial and Mining Supply Chain)

 

See the Project

Read the SIMSA Interview

 


Work with Rockford

Rockford Engineering has specific expertise regarding mechanical and automation design in the pipe handling industry. Our engineers’ combination of both practical in-the-field experience and technical training makes us a perfect candidate for projects such as this.

Our in-depth understanding of how pipe is made and processed can be an asset in both greenfield and brownfield initiatives. Whether designing a new system for your specific application or analyzing an existing system for improvement and optimization, Rockford can help.

We cater to all industries in both mobile and plant environments – contact us today!