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Posts Tagged ‘Denver Code Shop’

An interesting project has come to our shop that is leading to a new welding procedure. The project is a simple stainless steel pressure vessel, 6” diameter pipe, 0.432” wall approximately 18” long. While this seems overly simple it has led me to investigate the welding options we have qualified for stainless in our shop. We have stainless hardwire, flux core, stick, and TIG procedures but which one to use? Flux core fills very fast, hardwire is clean and neat, TIG has an artistic look when done right but is slower then hardwire and flux core. Stick welding is smoky and unless the welder is REALLY good it just doesn’t look as nice as the others. I’m beginning to think multiple processes. If we hardwire the root then no backing gas is required (meaning we don’t have to purge the inside of the vessel to remove any oxygen exposure on the back side of the weld) then we can fill the majority of the weld joint with either spray arc hardwire or flux core and finish with TIG. We get a solid, quick welded joint that looks like art! But I don’t have a weld procedure that includes three different welding processes. Do I need to break out some stainless steel scrap and weld up a coupon using the three selected processes and have it tested? Conveniently, I do not. Because I have Procedure Qualification Reports (PQR’s) for all three processes I can write a new procedure using the existing PQR’s. I can take the information from each PQR and implement a new procedure that includes all three processes. Each process must be noted on the new weld procedure and the essential variables must also be noted. One other item to be sure to review, the thickness of the additive PQR’s must yield the thickness range required for the intended joint. Maintaining documentation of all our welding processes and procedures makes this an easy accomplishment, an accomplishment that allows us to utilize our knowledge and history to go forward. If you like the way a certain welding process looks but have been told it costs too much or takes too much time, give us a call. We’ll help you find a happy medium that yields beautiful welding and cost effectiveness.

TIG Cover Pass

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So far 2013 has been all about NGL (Natural Gas Liquids) processing equipment.  Because Precision Pipe has been building process equipment for NGL for over 30 years 2013 has proven to be a very busy year.  In addition, our clients (new and old) are looking for expertise in the field of gas processing equipment design and fabrication.  We have nearly completed fabrication on our 2 NGL process plants this year and we have a 3rd plant on order.  These plants have been turnkey units with fully integrated controls and electrical.  We are still building 1 off pressure vessels and various TEMA type heat exchangers but skid packages seem to be whats driving our markets.

Gas Plant

Precision Pipe, LLC Gas processing plants

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Since 1980 Precision has built its business by designing and building gas processing plants, chemical and processing plant components, and skid packaged equipment including, tanks, HRSG, boilers, re-boilers, compressors, separators, heat exchangers, filtration systems, dehydration, and dew point control for natural gas processing facilities. Precision has also built several catalytic reactors for specialized applications, slug catchers, pulsation bottles, scrubbers, oxygen service vessels, flow meters, gas valve trains, accumulators, and complete skid packages.

Precision provides it’s customers with consulting, design, engineering, and ASME calculations. Precision can also provide in shop and mobile ASME vessel repairs and rerates, hydro testing, machining, welding (including ASME “R” stamped repairs, inspection services including borescope video inspection.

Most importantly, Precision is commercially distinguished as a business that offers it’s clients much more than a typical fabrication and welding shop.  Precision has built a reputation and is known to provide resources and knowhow for sustainable advantages in technology and project development. Precision uses it’s decades of experience and knowhow to offer value added solutions to our clients projects and fabrication needs.  This often saves time and money on projects and prototyping that bring long term value to our clients.

ImageIn 2013, Precision will continue our 33 year history building processing plants and equipment with a focus on natural gas processing. The biggest difference is our new, state of the art, 40,000 Square foot fabrication facilities. If you have a project and you need an experienced, knowledgable, and well qualified manufacturer please allow us the privilege to provide your company with a competitive quote.

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Having a market advantage is a huge goal for most companies especially during market down turns.  Often times a company may have such an advantage and not know it, or at least not know how to capitalize on such opportunities.  One market segment that Precision Pipe excels at and enjoys is building Dew Point Processing Plants also know as refrigeration plants, NGL, or Natural Gas Liquids Plants.  What sets Precision Pipe & Vessel aside from our competitors is we have many different approaches to building gas processing equipment that other fabricators don’t consider or offer to their customers.

Our approaches include remanufacturing used equipment in a quality manner giving the appearance the equipment is new (often times it is as good as new).  We also painstakingly examine and inspect each mechanical component to ensure reliability and give estimated time before component overhaul.  We also build complete brand new plants from the skid up.  All of our products are turn key with complete instrumentation and piping interconnect as specified by each customer.  As soon as the plant has been connected to utilities and the associated site piping our systems are ready to be started up and turned over to operations.

Our most recent gas plants have taken yet another approach that provide the longevity  and the associated technology of new and modern Gas Plants yet maintain the cost savings of remanufactured equipment.  Recently we have assembled a plant that used brand new wear components such as a refrigeration compressor, glycol pumps, instrumentation, heat exchangers, and other moving components.  However, we created substantial saving to our client by using ASME pressure vessels and a glycol re-boiler off of used equipment.  We simply identified vessels in our inventory and evaluated condition and specification according to the refrigeration plant.  Next, we transplanted the vessels onto the new skid and re-registered the vessels with the National Board.  This process cut months out of the fabrication schedule and reduced the cost of the plant by nearly 30% for our customer.

When it was all said and done we shipped a modern gas plant to our customer complete with computerized controls and modern instrumentation at a greatly  reduced cost.  We were also informed by our customer that our delivery was several months quicker then the next best offer.  As it stands today the plant has operated for nearly a year with no shut downs and only routine maintenance performed.  This has become a good case study for cutting costs and improving our customers ROI by using creative and alternative fabrication techniques.

Precision Pipe and it’s staff has fabricated nearly 100 NGL plants over the last 30 years that are operating in various locations in North and South America.  We have developed a reputation for finding good quality used equipment, rebuilding our customers antiquated systems, and building brand new equipment to operate in todays modern gas fields.  Precision Pipe

NGL Plant

Precision Pipe uses new and used equipment to build great products

is a fully qualified ASME code shop (U,R,S, & NB stamps) that specializes in gas processing equipment, gasification, alternative energy, and product development engineering and fabrication.

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Did you know that there are a few simple steps you can take to save quite a bit of money on your insurance?  No, it’s NOT switching to GEICO®!   Certifying your company with the State Cost Containment Board (Name varies from state to state) can make a big difference in the amount of Workman’s Compensation Insurance that your company pays out.  (And, it is so easy, even a Ca…you get the point.)  It is amazing that every company doesn’t go through the steps of cost containment to keep that money within their organization.

More importantly, cost containment is more than saving money – it is a commitment within your organization to provide a safe working environment for all.  This ethos can only be achieved through the constant effort of top leadership to promote safety within the organization.  Safety programs and open lines of communication are effective tools in keeping a safe work environment but without a constant push from the top, employees often become complacent which can lead to accidents.

If you haven’t already, begin a cost containment program within your organization.  Usually, a company needs to have a cost containment program in effect for one year prior to submitting to the certifying entity.  Though this process may seem tedious, it is worth creating an environment of safety and care as a core value.

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Material tracking is important.  We all know that.  This part of internal logistics is key when quoting jobs but is essential when working the job.  Nobody wants to be the reason for lost time, and if the reason is they can’t find the material, that is unforgivable.  Ensure you know what material you have and where to find it when it is needed.

While material tracking is important, of growing concern is the proper identification of the material.  PMI (Positive Material Identification) and  MTR’s (Material Test Requirements) are becoming necessities from companies to be part of the job package to properly identify the materials used for the job.  PMI uses a tool shaped like a gun and when aimed at any material, the trigger is pulled and the screen on the gun tells what material it is.  Simple?  Not hardly as training is required before you can use it.  Cost effective?  Possibly.  That depends on the size of your company and how much material goes through it’s doors.  The PMI tool costs upwards of $50,000, so this is not for the small business that is trying to get by in this economy.  The more cost effective method of material identification is the utilization of MTR’s.  MTR’s are copies of the paperwork telling where material comes from, it’s heat number, chemical composition, physical dimensions, and other details.  You can have your material supplier provide this paperwork when you order your material.  When you receive your material, be sure to verify the heat numbers on the material with the heat numbers on the MTR’s.   It doesn’t help to have an MTR if it does not match the material you have.  While not as quick as using the PMI tool, MTR’s will do the trick as long as you use some diligence, keep your paperwork up to date and ensure the heat number is prominent on material, even after it is cut.

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At Precision Pipe we have built a variety of vessels configured in every way one could possibly imagine.  Yet, we are always surprised by new ideas that come through our doors.  As a company that strives to exceed our customers expectations we are always looking for new ways to save money and bring value to our clients projects.  Recently, we were asked to bid on stainless steel vessels that are ASME rated above 1000 PSIG.  We returned a bid as requested but we also supplied an alternative bid using carbon steel that still meet the needs of the project but had the potential to save several thousand dollars off each pressure vessel.

How do you make a stainless steel vessel out of carbon steel?  There is the age old technique of cladding a vessel with stainless steel welding wire.  However, it is ugly, time consuming, and even distribution is unlikely.  In this particular case the esthetics of the vessels (inside and out) were equally important as the function.  Thus, we needed to supply quality, function, and appealing form to the project. What we have accomplished is Precision Clad.  We have effectively used seal welded stainless steel liners with stainless head and nozzles.  Using this methodology we have made the entire inside surface a stainless steel ASME pressure vessels while replacing the expensive, thick, and  high pressure shells with less expensive carbon steel.  In times like these Precision Pipe knows our clients need ways to get their projects finished in economically feasible ways.  However, this is not a new trend for Precision Pipe but an ethos of our company with 30 years of practice.

The results of these vessels have been well received and the savings have been remarkable.  In addition the vessels look great inside and out, they are 100% functional as corrosion resistant, this is Precision Clad.

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