1) The ECOVIX pipe shop in Rio Grande do Sul, Brazil fabricates pipes for 8 FPSO platforms and is working to modernize and automate the fabrication process. 2) The pipe shop is equipped with cutting machines, fitting tables, welding machines, and orbital welders to cut, assemble, and weld carbon steel, stainless steel, and copper-nickel pipes ranging from 2-36 inches in diameter. 3) The pipe shop's production capacity is expected to increase from processing 7 tons of pipe per day currently to 14 tons per day at peak production as it expands its facility and workforce.

1. Pipe ShopCapacityECOVIX - Engevix ConstruçõesOceãnicas - Pipe ShopManager: R.S.Wagemaker
31-08-2012, RioGrande – RS - Brazil
1
Introduction
SinceDecember 2010 ECOVIX – Engevix Construções Oceãnicas –is operatingthe shipyard in Rio Grandedo Sul
for the fabrication of 8 FPSO platforms.From the beginning of the construction of this shipyard,ECOVIX is
trying to modernize and automate the total fabrication processin all departments.In this report you can find a
summary of the equipment andanexplanationof the production capacity inthe Pipe Shop in(ERGI).
Equipment
Cutting department:
 3 HGG (CNC) PipeProfiling Cuttingmachines,all 3 machines areequipped with a plasma unit,1 is able
to cut Stainless Steel and CuNi pipes and 1 is ableto cut stock lengths of 12000 lengths.This machine
is also equipped with an automated infeed-system.
 After cutting the parts to fabricatespools weprepare the pipe ends by usinggrindingmachines, atthe
same time when we receive the flanges and connections we prepare everything in the same area.
When all thepipes and connections areprepared all parts move on to the assembly department.
Assemblydepartment:
 For the largediameter pipes (10” - 36” straightspools) assembly wehave installed in our shop a big
fittingtable (own design).The table is totally aligned to 1 center line.What enables us to put the
flanges againstuniversal flangeplates,put the pipes on pipe trolleys and assemblethem to the flanges
quick.In the near future we gain more time by installinga laser measuringsystemto speed up the
dimensional check to liberatethe spools for welding.
 For the small diameter ( 2” – 10” straightand curve´s and tee´s ) assembly we have an area where we
use universal weld fixturetables,these tables are also leveled and equipped with several universal
fixingtools which enables us to make 1 fixturefor, for example 20, equal pieces to produce fastand
more accurate.
 On the Weldingfixture tables we also fabricatesomebig curved spools which we can´tfit on the big
table.
 When the spools arealigned they arebeing tack welded, usinga TIG weld, at the tables.
Now the spools arepassed to the weldingdepartment.
Welding department:
 For the largediameter spools wehave a PEMA Column & Boom welding machine. This machineis
equipped with a Lincoln Electric Power Wave S350 STT system. An STT system is ableto make root
passes usinga MIGwelding process,which is faster than usingthe conventional TIG process.Because
we can make all the passes,for the joints atthe spools,with the same machinethis setup is ideal to
weld the joints for the largediameter spools.The machineis generally used to weld the long straight
spools with,sometimes, a Tee or curve attached.

2. Pipe ShopCapacityECOVIX - Engevix ConstruçõesOceãnicas - Pipe ShopManager: R.S.Wagemaker
31-08-2012, RioGrande – RS - Brazil
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 For the short, largediameter, spools weuse several PEMA positioners to make the root passes and
weld finishes also with (in the near future 7 other ) L.E. STT weldingmachines.
 Also is our pipe shop equipped with conventional weldingmachines to make root passes usingTIG
processes and to finish the joints on several other PEMA positioners.
 For Stainless steel and CuNi our pipe shop is equipped with 2 Orbital weldingmachines ( TIG process )
the SS and CuNi spools arein total cut and fabricated in a separatearea in our pipe shop. To minimize
the spaceneeded and of its very high quality and productivity standard,we have chosen for the use of
an orbital weldingsystem. The largestdiameter for usingthese machines is 20 “ ( which is the largest
CuNi pipes we need to process ).
 For the difficulttype of spools,where we are unableto use the orbital welders,we will useFronius
special TIGweldingmachines to make the joints by hand. Now we have 2 machines in our shop.
Equipment summary:
- 3 HGG SPC 800 pipe profilingmachines Plasma KjellbergFF 450 and Oxyfeul equipped.
- 1 largediameter flange fittingtable ( own design ).
- 7 Demmeler welding fixturetables with tools for fittingpipes.
- 1 PEMA Column & Boom automated welding machine. MD 1x1 with CNC controlled rollerbed system.
- 8 PEMA APS 1500 welding positioners,remote speed controlled.
- 3 ( 8 in back order ) Lincoln Electric Power Wave S350 STT Multi process weldingmachines.
- 30-40 Lincoln Electric Flextec 450 multi process weldingmachines.
- 2 Fronius TransPuls Synergic 5000 TIGweldingmachines.
- 2 AMI model 15 Orbital weldingmachines + 1 model 79 welding head, TIG process.
- PowerMig roller bed setup for largediameter pipes 1 motorized and 3 non-motorized.
- 4 DWT cold beveling machines to make special shaped bevels for welding Stainless Steel and CuNi
pipes.2 type MF3iw Pneumatic for small diameter pipes and 2 type MF5iw-II Pneumatic for large
diameter pipes.
- For internal transportation purposes thepipe shop is equipped with 2 x 16 T overhead cranes and
4 x 2 T ( 7 m length ) and 2 x 2 T ( 11 m length ) Semi portal cranes.
The Pipe Shop has currently a sizeof about 1800 m² in October we are extending this until 2400 m². When the
block buildingfacility in ERGII is ready to be operated, we aredoublingthe sizeof the shop to 4800 m². In the
extended area we intend to build a work shop of 700 m² where we aregoing to fabricateall thesupports and
other small parts to install all thespools in the FPSO hulls. In this small shop wewill install several machines
which make us ableto fabricatethose parts and also we will usea small platecuttingmachine. The other part
of the extension we are going to use to fabricateStainlessSteel and CuNi spools ( in an already build separated
area ).

3. Pipe ShopCapacityECOVIX - Engevix ConstruçõesOceãnicas - Pipe ShopManager: R.S.Wagemaker
31-08-2012, RioGrande – RS - Brazil
3
Production capacity
To explain the production capacity of the Pipe Shop we need keep in mind we are constantly improvingour
production capacity duringthe total project to reach the maximum that is possible.Also because we have
not the total area inuse as explainedabove,the numbersmentionedbeloware constantlychanging
but are reasonably accuratefigures to consider as production capacity.
Total Pipe Tonnage / FPSO :
Total Weight
( T )
Carbon Steel
( T )
Mariloy
( T )
Stainless Steel
( T )
CuNi
( T )
Calculated by PCP
( MH/T )
Expected Peak
( T/Month )
1116 829 122 115 60 150 200
Current production capacity ( 30-08-2012 ) :
Amount of
workers
Average
MH/week
Average
T/day
Average
T/m
MH/ m Average pipe
diameter
Percentage
Mariloy
MH/T
50 2200 7 152 9533 12” 10 % 63
Estimated production capacity ( 30-12-2012 ) :
Amount
of workers
Average
MH/week
Average
T/day
Average
T/m
MH/
m
Average
pipe
diameter
Percentage
Mariloy
Percentage
SS / CuNi
MH/T
100 4400 10 200 19.067 12” 10 % 8 % 95
Estimated production capacity ( Peak ) :
Amount of
workers
Average
MH/week
Average
T/day
Average
T/m
MH/
m
Average
pipe
diameter
Percentage
Mariloy
Percentage
SS / CuNi
MH/T
160 7040 14 300 30.507 12” 10 % 15 % 102
Attached are some pictures of the equipment, listed in this report, for reference and more explanation.

4. Pipe ShopCapacityECOVIX - Engevix ConstruçõesOceãnicas - Pipe ShopManager: R.S.Wagemaker
31-08-2012, RioGrande – RS - Brazil
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HGG SPC 800 Pipe profiling machine.

5. Pipe ShopCapacityECOVIX - Engevix ConstruçõesOceãnicas - Pipe ShopManager: R.S.Wagemaker
31-08-2012, RioGrande – RS - Brazil
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Large spool fitting table.

6. Pipe ShopCapacityECOVIX - Engevix ConstruçõesOceãnicas - Pipe ShopManager: R.S.Wagemaker
31-08-2012, RioGrande – RS - Brazil
6
Demmeler welding fixture tables.

7. Pipe ShopCapacityECOVIX - Engevix ConstruçõesOceãnicas - Pipe ShopManager: R.S.Wagemaker
31-08-2012, RioGrande – RS - Brazil
7
PEMA C&B welding Machine.
PEMA Positioner.

8. Pipe ShopCapacityECOVIX - Engevix ConstruçõesOceãnicas - Pipe ShopManager: R.S.Wagemaker
31-08-2012, RioGrande – RS - Brazil
8
AMI Orbital welding machine.