Fluor Petrochemical Case Study

FLUOR PETROCHEMICAL CASE STUDY >

Petrochemical Plant Takes Delivery Of 43 MasterMovers

MasterMover was approached by a world leading engineering and construction company to design and build a custom solution that could safely move sensitive and awkward loads at an oilfield in Kazakhstan.

Problem

In the energy industry, there is a need for load moving solutions that can work in compact areas, around tight corners, at height and over tricky flooring – all whilst still delivering outstanding safety and efficiency gains.

Plan

Led by a dedicated Project Manager and Mechanical Design Engineer, MasterMover developed a modified electric tug – one that was cleverly adapted to the stringent demands of a particular and unique working environment.

Solution

Despite the short lead time for the design and production of a new product, the MasterMover team delivered ahead of schedule – meeting every single requirement along the way.

The Problem

MasterMover was approached by Fluor, a world leading engineering and construction company, to design and build a custom solution that could safely move sensitive and awkward loads at Tengiz oilfield in Kazakhstan.

The completely new stainless steel machines needed to be specially treated to comply with the ATEX Zone 1 and EAC directives and as such, had to be suitable for use in areas where there was a risk of potential explosion.

The Process

Fluor invited different material handling companies to take
part in a tendering process, scrutinizing alternative load
moving methods including overhead cranes, winches and
motorized skates.

All were rejected on the grounds of safety and efficiency
concerns – with a key specification being that the eventual
solution needed to be able to move a load of more than
11,000 lbs across grating and around tight corners using
client specified carts.

A modified electric tugger was the only answer – albeit one
that was cleverly adapted to the stringent demands of a
particular and unique working environment. In addition, the
client needed to be confident about working with a company
that had the design and engineering project management
capabilities to deliver a custom order of this magnitude.

The overall project deliverables were constrained by a
rigorous client documentation pack, the need to adhere to
strict international standards and a demanding timeline.

The Plan

Led by a dedicated Project Manager and Mechanical Design
Engineer, an in-depth engineering study was required to collect
detailed application data. This had to take into consideration
several defined turns of various width and tightness.

The study allowed MasterMover’s Special Projects team to
develop a prototype. Working alongside Pyroban, a specialist
provider of ATEX conversions, the prototype was based
on the most challenging load moving task faced. It would
also ensure the new machines would work in a potentially
explosive environment.

ATEX conversion is a complex and time-consuming process,
requiring every single electrical component within the body of
a machine to be stripped back and re-engineered separately
before being brought back together during assembly.

The prototype, which was a modification of an existing
MasterMover MasterTow, validated the integration of the
electrical enclosure into the machine body through a number
of thermal tests in accordance with ATEX Zone 1 restrictions.

After a successful client demonstration at MasterMover
around a simulated course on site specific flooring,
production was ready to commence. As build was towards the end of the project schedule – with potential financial penalties
for even a delay of 24 hours – speed and accuracy was of the
essence.

To minimize any potential for delay and disruption, a new
just-in-time production layout was created at MasterMover’s
manufacturing headquarters in the UK. Meanwhile, an
already highly skilled MasterMover production team
undertook additional ATEX training.

Specialist assembly tools and jigs were designed and
manufactured specifically for the build process. These
included a support frame to hold the partially wired ATEX
enclosure above the main machine carcass during assembly,
and a motor loading trolley (which the client would go on to
use for the subsequent maintenance of the machines).

Batch production allowed third party inspectors to visit at
regular points to check that the client’s expectations and
international standards were being met throughout.
As well as the 39 custom machines, Fluor also ordered 4
stainless steel MasterTugs, spare parts and couplings.

The Result

Despite the short lead time for the design and production
of a new product, the MasterMover team delivered ahead of
schedule – meeting every single requirement along the way.
The completed project is now attracting interest from around
the world, as well as from other manufacturing sectors.

Thanks to the combination of safety first features and power,
it is now possible to keep employees protected from the
dangers of flammable vapors and still harness the load
moving capabilities of a MasterMover.

This custom solution is the latest in an innovative range of
electric tuggers and tows that are used by many different
industries to improve productivity, create smoother workflows
and reduce non-value-added activities.

“The eventual solution needed to be able to move a load of more than 11,000 lbs across grating and around tight corners using client specified carts.”