ZAP was contracted to make a structural analysis of an existing four stage concrete preheater tower at a cement plant. Engineering services included developing a design basis and determining what load cases would be applied to the tower.
ZAP produced detailed engineering documentation, 3D models and component fabrication drawings for a client that wanted to create and own the separator design.
Plant maintenance requested improved access to a large duct’s slide gate above the roof level. A complex geometry was required to provide a platform that was supported by exterior building framing to avoid placing any load on existing roof trusses and yet account for operation of an adjacent roof hatch and maintain access to the slide gate components.
A steel manufacturer operates two 200-ton bridge cranes in their melt-shop for daily operations. For production and safety improvements they requested ZAP design fixed access platforms at each end of the building so that the cab operator could wash their own windshield periodically during shift. The original building had been modified and the original crane had been replaced since design drawings were produced. Our design efforts for this scope were complemented by a 3D scan of the facility for a higher confidence that our design had taken as-built conditions into account.
Central Vacuum System A manufacturing facility seeking to improve silica dust cleaning operations requested ZAP design a central vacuum system to cover critical areas of their seven-story crushing and screening building. For a more complex manifold layout through such a congested space, ZAP was able to provide a laser scan of the facility and design […]
A cement plant customer is planning to add equipment that will require new electrical cables for power, which will be supported by existing towers.
A manufacturing customer is replacing specialty transformers across many of their plants and the new model is heavier than the unit that had been installed before. The installation is taking place on the sixth floor of their production facility
During a plant outage, a cement customer found that their kiln lifting beam (or saddle) was buckling due to the compression forces between the kiln and the hydraulic cylinders used to lift the kiln off its trunnion rollers.
ZAP was contracted to modify an existing dome withdrawal system and convert the reclaim system from a mechanical auger to an aerated floor.
This Greenfield compressor station in Lea County, NM receives rich natural gas from an existing gathering system at 40-60 psig and compress it to 1,050-1,300 using Six (6) leased compressor skids driven by Caterpillar G3608 A4 gas engines and dehydrated to 7 lbs/MMSCF.
ZAP completed the engineering, procurement, and construction to convert an existing gas processing plant to a compressor station with inlet liquid separation, amine treating, dehydration and water separation, and disposal.
Chemical Formulation Addition ZAP completed the engineering and design to allow a new formulation process to be produced at an existing chemical processing facility. New process chemical storage, including bulk formula storage and truck load out was included in design. ZAP also completed a 3D scan of the facility, which allowed the new design to […]
ZAP completed the mechanical and structural design for a compressor and condenser upgrade project at an Anhydrous Ammonia Terminal. The project included replacing existing water-cooled condensers with two Wet Surface Air Cooler Ammonia Condensers, which included a water treatment system for each unit.
Well Pad Gathering Projects ZAP completed work on pipelines from nine well pad sites that each required the install of an oil gathering, produced water, and freshwater pipeline lateral. Pipeline sizes included 12, 8, and 6 inch lengths, ranged from 500 LF to 7,000 LF. Scope included laying out launchers, receivers, valve sites, and tie-ins […]