Modular System: Design, Manufacture, Installation, and Commissioning

The Challenge

A global leader in the international offshore drilling waste market required an engineering solutions provider to assist with the development and manufacture of a complex product to process drilling waste at source.

The product required DNV approval for steel fabrication, ATEX approval for electrical installation in zone 1 hazardous areas and other third-party certification. The system design and manufacturing processes had to be robust, and reliable with the capability to operate in the harshest offshore environment.

JBS were contracted to work with our client to manufacture the product, on a turnkey basis, from design drawing review to steel fabrication, mechanical & COMPEX electrical installation, through to final assembly and commissioning at our Peterhead facility.

Client personnel were based at JBS for the duration of the project and a time lapse video was completed to record the manufacturing process.

The Solution

JBS worked with the client to develop the product, identify the material requirements and the commence the construction. Client personnel were provided with office facilities at JBS, during which a “one team” approach was developed, to integrate the project team and ensure safety was the number one priority at all stages throughout the production schedule.

The product uses a process of thermal desorption to separate drill cuttings and associated materials into their three constituent parts – oil, water and solids – for recycling and reuse.

JBS manufactured the complete unit, consisting of four modules: engine module, process module, mill module, feed module complete with all auxiliary equipment.

Prior to final deployment, a trial fit was conducted at our Peterhead HQ to assemble the complete system and ensure that the installation and integration of all components were fully operational.

Commissioning of the system was completed by the client.
 

Conclusion

JBS, working closely with our client, delivered the project, on schedule and on budget. The complex design also considered the logistics for transporting the equipment all over the world. The result was that the system design incorporated an overall footprint that did not require a wide load for road transport. Given the size of the equipment this was a challenge!

The equipment is now fully operational in the Arabian Gulf and demonstrates JBS’s ability to deliver complex engineering solutions, working in partnership with our client.