Project scope

Remove 6" liquid line and 3" valves from the system and replace with new piping/units to rectify leakage issue

The Client

Cargill is a family run American company supplying food, industrial and agricultural solutions globally. With a long linage tracing back to foundation in 1865 and expanding massively to a $165 billion revenue company in 2022, producing high-quality work for Cargill to rectify emergencey line issues showcases the caliber of projects we can undertake successfully.

Our Project

SHG Engineering were involved in a 6" liquid line upgrade to the ammonia system used to cool an area of the production facility.  To do this we had a brief survey of the project on-site at Cargill Wolverhampton, gaining key information of required pipe sizes and a risk assessment with attention to the potentially hazardous medium of ammonia.

After the survey was completed, information was relayed back to the CAD designer who highlighted the relevant information on the PNID drawing provided by the client before producing a detailed weld map of the job at hand, including welder information, pipe/elbow sizes, and heat numbers for the pipe used to give full traceability back to the material certs for each section of pipe used.

A full set of risk assessments and method statements were then provided to the client before our expert welder and pipe fitter arrived on site and successfully performed the 6" line upgrade with use of a 3rd party NDT Engineer to ensure the welds are to the highest quality. The full QA technical document regarding the works including all welder qualifications, NDT Reports, Weld maps and material certifications was then produced to the client.

After this upgrade work was completed, Cargill suffered a major fault in a different area of the system due to old piping causing an ammonia leakage from the 3" valves, due to our efficiency in completing the upgrade they commissioned SHG to return to site and perform this emergency repair.

This section of the project was to be completed under an extremely strict time frame with the plant requiring to be in operation within 2 days from the found leakage, immediately a full risk assessment was performed and material/valves, with full certification and declaration of conformity, procured. Weld maps were created and the PNID updated to highlight the area of the new works as a team of engineers attended site including highly trained welder and pipe fitters to ensure the work was completed within the time frame required. The job was successfully completed quickly and efficiently to our high standards with no corners cut, including full material traceability and 3rd party non-destructive testing for proof of good engineering practice. Upon job completion the client was then provided with our updated QA technical pack detailing both the original upgrade works and the emergency valve replacement.

Summary

Overall the project was a success with the original upgrade works and emergency repair works completed to the highest quality and supplied with all documentation to detail the works and material used, impressing our client.