Expansion Barrel

Project Overview

Our firm was engaged by a leading energy sector contractor to provide specialized engineering and design services for a set of large-diameter Expansion Barrels, critical components in a major infrastructure upgrade. Following award of the engineering scope, we were responsible for detailed material selection, structural analysis, and fabrication support.

Scope of Work

• Engineering Design & Material Selection:

  
  

  Delivered comprehensive engineering packages incorporating wear-resistant Chromium Carbide (CrC) overlay, optimized internal diameters, and wall thickness calculations in compliance with applicable industry codes.

  
  

  The design also accounted for thermal expansion behavior during operation, with specific measures taken to prevent lateral “snaking” of the barrels during hot and cold fluid transfers — a critical consideration for maintaining alignment and long-term mechanical reliability.

• Structural & Pressure Analysis:

  
  

  Performed Finite Element Analysis (FEA) and pressure testing calculations to ensure design integrity under abrasive service conditions involving bitumen, sand, and water.

• Hydrostatic Test Jig Design:

  
  

  Designed a custom hydrostatic testing fixture to facilitate safe and effective pressure testing prior to field installation.

• Comprehensive Deliverables:

  • Provided full calculation reports and design documentation

  • Delivered detailed 2D and 3D CAD drawings, supporting models, and bill of materials

  • Supplied all information required for fabrication, inspection, and assembly

  
  

Outcome

Our firm successfully delivered a robust, code-compliant engineering package that met the demanding operational requirements of the project. This engagement highlights our capability to provide complete, end-to-end engineering solutions within complex, multi-stakeholder projects in the energy sector.