Case Study: D61 Dozer On-Site Modifications
Client: Recycling Processor
Industry: Industrial Equipment Handling
Location: Dockside Port
Featured Services: Loler Testing, Puwer Testing, Welding, Mobile Welding, Modification Design, Modification Fabrication Modification Installation
Project Overview
National Plant Solutions (NPS) was engaged to perform critical on-site modifications to a D61 Dozer essential for continuous production operations. The machine’s role involved handling shredded scrap metal and being lifted into ship holds via crane, necessitating enhancements to ensure operator safety and equipment integrity.
Challenges
Non-Removable Equipment: The Dozer was vital to daily operations and could not be taken off-site without disrupting production.
Harsh Operating Conditions: Regular exposure to shredded scrap metal and crane lifting posed risks to both the machine and operator.
Safety Compliance: All modifications required adherence to stringent safety standards, including independent weld inspections and LOLER testing.
Solutions
Custom Fabrication: Designed and installed bespoke cab window guards to protect the operator and ram guards to safeguard critical components.
Lifting Point Installation: Fitted OEM lifting points with independently verified welds, accompanied by custom guards to prevent impact damage.
Comprehensive Planning: Conducted a thorough site survey, developed Risk Assessments and Method Statements, and coordinated with third-party partners for on-site weld and LOLER testing.
Minimal Downtime Execution: Deployed a two-person fabrication team on a Saturday to complete the work, ensuring zero disruption to the client’s Monday-to-Friday operations.
Results
On-Time, On-Budget Completion: All modifications were successfully executed within the agreed timeframe and budget.
Certified Safety Compliance: The Dozer passed all weld inspections and LOLER testing, confirming the integrity of the modifications.
Client Satisfaction: The client praised NPS for delivering a unique on-site solution, eliminating the need to remove the equipment and thereby preventing operational downtime.
Conclusion
This project exemplifies NPS’s capability to deliver complex, safety-critical engineering solutions directly on-site. Through innovative design, meticulous planning, and expert execution, NPS ensured uninterrupted production for the client while meeting all safety and compliance standards.