Multi-Discipline Engineering for Revolutionary Demonstration Plant

[fusion_builder_container hundred_percent=”no” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” overlay_color=”” video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”20px” padding_right=”” padding_bottom=”20px” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_3″ layout=”1_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” undefined=”” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”10px” padding_right=”10px” padding_bottom=”10px” padding_left=”10px” margin_top=”” margin_bottom=”” animation_type=”fade” animation_direction=”down” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

Project

PureCycle Feedstock Evaluation Unit (FEU)

Location

Irontown, Ohio

[/fusion_text][fusion_separator style_type=”none” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”” top_margin=”15px” bottom_margin=”15px” border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”” alignment=”center” /][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

Background

EN Engineering, as part of the Engineering, Procurement, and Construction (EPC) team led by Denham-Blythe Company (Lexington, Kentucky), provided multi-discipline engineering, permitting, and process safety management services to PureCycle Technologies, Inc. (Chicago, Illinois) for their revolutionary Feedstock Evaluation Unit (FEU). The FEU utilizes a groundbreaking, patented process developed by Proctor & Gamble which purifies polypropylene resin, a material which makes up a large percentage of recycled plastics, so it can be used in food-grade applications.

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”2_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

Challenges

Because the project involved brand new technologies that had never been applied outside of a laboratory, it presented a number of unique challenges. Utility requirements and building configurations changed often, as process models were updated based on the latest laboratory data. The structural components, piping, and utility connections were designed to facilitate field installation of the modular process units after the building was erected. The nearly 45’ tall pre-engineering steel building also houses an on-site laboratory for product testing and a control room to monitor operations. The team demonstrated flexibility and skill in addressing these challenges throughout the project.

Solutions

The Denham-Blythe/EN Engineering team was responsible for the design-build construction of all site, civil, architectural, and utility system components except for the process modules, which were designed and fabricated by Koch Modular Process Systems of Paramus, New Jersey. Working with subcontractors, the teams provided civil engineering, mechanical engineering, process engineering, electrical engineering, geotechnical engineering, permitting, environmental services, architectural, and process safety management services for the project. Despite working with untried technologies that were being applied outside of a laboratory for the first time, the team successfully managed design and site challenges with flexibility and expertise. EN Engineering will continue to work with the client on a commercial-sized polypropylene resin purification facility on the same site which will process 100,000,000 lbs. per year of recycled polypropylene.

“The team encountered several detours… and demonstrated flexibility and skill in addressing them along the way”

[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Sample Stations Designed and Installed to Resolve Deficiencies

[fusion_builder_container hundred_percent=”no” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” overlay_color=”” overlay_opacity=”0.5″ video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”20px” padding_right=”” padding_bottom=”20px” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_3″ layout=”1_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” undefined=”” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”10px 10px 10px 10px” margin_top=”” margin_bottom=”” animation_type=”fade” animation_direction=”down” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Project

System design, procurement and construction support for sample stations

Location

Texas

[/fusion_text][fusion_separator style_type=”none” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”” top_margin=”15px” bottom_margin=”15px” border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”” alignment=”center” /][fusion_text]

Background

Our client, the second largest refinery in the U.S., surveyed more than 700 existing sample stations in their various refinery units and discovered that over 400 had environmental and/or safety deficiencies. The client prioritized the stations according to the severity of the concerns and called on EN Engineering to execute engineering, design, procurement and construction for the $31 million project to replace deficient sample stations.

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”2_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Challenges

The sample stations, which were located in every production unit of the refinery, had to be replaced while the refinery was in operation, or during scheduled turnarounds. In addition, many of the sample stations were high priority and required demanding replacement deadlines. The design team demonstrated flexibility by responding to ongoing changes in priorities, turnaround schedules, operational needs, and safety concerns throughout the project.

Solutions

A dedicated team was embedded at the client’s site to work with plant personnel and executed the project from concept to installation with additional support from EN Engineering employees across the country. The team collected the necessary information and developed detailed plans to install the sample stations. The required documentation included P&IDs, data sheets, isometric drawings, installation details, operational manuals, and spare parts lists. EN Engineering also developed purchasing and tracking specifications for the procurement of each sample station and purchased $1.4 million in materials and equipment. Following procurement, the EN Engineering team provided field construction support. The project required more than 35,000 hours, and the 400 sample stations were designed, installed, and operational ahead of the challenging deadlines.

“Many of the sample stations were high priority and required demanding replacement deadlines.”

[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Fall Protection Hazards Mitigated to Enhance Safety

[fusion_builder_container hundred_percent=”no” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” overlay_color=”” overlay_opacity=”0.5″ video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”20px” padding_right=”” padding_bottom=”20px” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_3″ layout=”1_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” undefined=”” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”10px 10px 10px 10px” margin_top=”” margin_bottom=”” animation_type=”fade” animation_direction=”down” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Project

Platform Upgrade for Fall Hazard Remediation

Location

Catlettsburg, KY

[/fusion_text][fusion_separator style_type=”none” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”” top_margin=”15px” bottom_margin=”15px” border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”” alignment=”center” /][fusion_text]

Background

Working together, LJB, Inc., a firm specializing in safety and environmental engineering, and EN Engineering offer expert Fall Hazard Analysis and Remediation services. The client, one of the largest crude oil refiners in the U.S., worked with LJB to complete a Fall Hazard Analysis, and EN Engineering followed up by performing the detailed engineering and design of the corrective actions identified.

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”2_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Challenges

The project required buy in from a variety of personnel, including engineering, maintenance, construction, and operations, so ongoing and thorough communication was critical for success.

Solutions

A comprehensive Fall Hazard Analysis was completed to identify deficiencies throughout the refinery. Following a feasibility study to confirm the deficiencies had not already been mitigated and the egress items were required for operations, EN Engineering developed and presented cost projections to the client. Upon budget approval, the team performed detailed engineering and design to correct the issues identified by the Fall Hazard Analysis, including the design of platforms, ladders, handrailing, grating, and swing gates.

EN Engineering has helped the client organize the project to produce a steady flow of engineering deliverables that coincide with construction schedules. Each segment of work has been completed on budget and on time. The client can now be assured that the fall protection deficiencies have been, or will soon be, corrected and they are in compliance with OSHA standards.

“The team performed detailed engineering and design to correct the safety deficiencies identified by the Fall Hazard Analysis.”

[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Landfill Closure Meets Environmental Compliance Regulations

[fusion_builder_container hundred_percent=”no” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” overlay_color=”” overlay_opacity=”0.5″ video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”20px” padding_right=”” padding_bottom=”20px” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_3″ layout=”1_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” undefined=”” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”10px 10px 10px 10px” margin_top=”” margin_bottom=”” animation_type=”fade” animation_direction=”down” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Project

Landfill Closure for Steel Facility

 

Location

Ashland, Kentucky

[/fusion_text][fusion_separator style_type=”none” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”” top_margin=”15px” bottom_margin=”15px” border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”” alignment=”center” /][fusion_text]

Background

A large steelmaking facility wanted to formally close an 11.2 acre debris landfill and retained EN Engineering to complete the closure in compliance with state regulations.

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”2_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Challenges

The existing landfill was not properly capped, and stormwater runoff was not being properly managed. The closure plan had to comply with state regulations and utilize plant process byproduct as a capping material.

Solutions

The client retained EN Engineering to provide detailed engineering services to properly complete the landfill closure. These services included surveying, civil engineering design and construction observation, all in compliance with state regulations. The deliverables included design drawings, specifications, and a construction survey layout that were monitored by EN Engineering via construction observation throughout the implementation process. The capped landfill was compliant with state environmental regulations and the stormwater runoff was properly managed, eliminating the potential for an environmental hazard. Working with EN Engineering, the client had a single source for detail design, construction management, and maintenance plan development.

Working with EN Engineering, the client had a single source for detail design, construction management, and maintenance plan development.

[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Evaluation and Installation of Stormwater Management System

[fusion_builder_container hundred_percent=”no” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” overlay_color=”” overlay_opacity=”0.5″ video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”20px” padding_right=”” padding_bottom=”20px” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_3″ layout=”1_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” undefined=”” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”10px 10px 10px 10px” margin_top=”” margin_bottom=”” animation_type=”fade” animation_direction=”down” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Project

Evaluation and Installation of Stormwater Management System

 

Location

Haverhill, Ohio

[/fusion_text][fusion_separator style_type=”none” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”” top_margin=”15px” bottom_margin=”15px” border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”” alignment=”center” /][fusion_text]

Background

The client, a chemical processing company, retained EN Engineering to evaluate a poorly performing stormwater collection system and develop a solution.

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”2_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Challenges

The facility owned a stormwater collection system that was not providing effective stormwater management. The existing cast iron piping was degraded via the existence of corrosive chemicals. The suspected corrosion was confirmed with remote imaging that traversed the system recording images of the route. The client desired a new collection system that would resist corrosive chemicals and that could be installed with very limited operational disturbances.

Solutions

EN Engineering was retained to analyze and evaluate the problem and develop a solution.  The corrosive chemicals were analyzed, and the stormwater runoff was calculated for the affected area. To begin the design, EN Engineering surveyed the existing trenches, cleanouts, and manholes in an effort to map the existing system. In addition, the client provided various underground drawings of the process units to further determine clearances and elevations of the new system. The information was compiled to produce design drawings and specifications for the installation of the new system. New trenches and collection points were determined and designed into the new system to address drainage issues around operating equipment. EN Engineering also solicited local vendors for material pricing and assisted in contractor selection. A construction project manager from EN Engineering was retained to oversee the demolition of the existing system and installation of the new system.

The new design utilized a high-density polyethylene collection system to replace the existing cast iron collection system that had been degraded by corrosive chemicals. It was installed through two process units within the facility with no production outages. The new system, which meets regulatory compliance for stormwater management, resulted in improved stormwater collection and disposal for the client.

The new system resulted in improved stormwater collection and disposal for the client.

[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Design, Demolition, and Installation of Replacement Flare Stacks

[fusion_builder_container hundred_percent=”no” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” overlay_color=”” overlay_opacity=”0.5″ video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”20px” padding_right=”” padding_bottom=”20px” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_3″ layout=”1_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” undefined=”” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”10px 10px 10px 10px” margin_top=”” margin_bottom=”” animation_type=”fade” animation_direction=”down” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Project

Design, Demolition, and Installation of Replacement Flare Stacks

 

Location

Kentucky

[/fusion_text][fusion_separator style_type=”none” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”” top_margin=”15px” bottom_margin=”15px” border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”” alignment=”center” /][fusion_text]

Background

Our client requested a detailed engineering design package for the installation of replacement flare stacks for two vessels for their steel manufacturing plant.

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”2_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Challenges 

The client had two, 20-year-old flare stacks with internal corrosion from the process environment, and the stacks had begun to lean. A temporary solution was needed to enable continued operation until the flare stacks could be replaced. The client also requested a full-service solution for the design and off-site fabrication of flare stacks for two vessels. In addition, the client requested a plan for demolition and installation of the new stacks and on-site supervision of the project.

Solutions

EN Engineering provided detailed design for temporary support for the existing stacks, allowing them to remain in operation until new stacks could be designed, constructed, and installed. EN Engineering also prepared a detailed engineering design package for the installation of the two replacement flare stacks. As a benefit to the client, the new stacks were redesigned with silencers, which were relocated to the roof to grant easier maintenance access. New platforms were designed to aid in access to flow control and flare equipment. The EN Engineering team provided 24/7 staffing to supervise both demolition and installation. The stack replacement was completed on schedule and under budget with no safety incidents.

“The engineering was under budget and on schedule. The quality was excellent. Everything fit just right, and there was no rework.” – Client Project Manager

[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Thermal Oxidizer Control System Upgraded On Time and On Budget

[fusion_builder_container hundred_percent=”no” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” overlay_color=”” overlay_opacity=”0.5″ video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”20px” padding_right=”” padding_bottom=”20px” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_3″ layout=”1_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” undefined=”” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”10px 10px 10px 10px” margin_top=”” margin_bottom=”” animation_type=”fade” animation_direction=”down” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Project

Thermal Oxidizer Control System Upgrade

 

Location

West Virginia

[/fusion_text][fusion_separator style_type=”none” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”” top_margin=”15px” bottom_margin=”15px” border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”” alignment=”center” /][fusion_text]

Background

Our client, a leading global specialty chemical company, operates a chemical manufacturing facility that produces maleic anhydride for use in the manufacture of boats, automobiles, buildings, piping, cosmetics, foods, and beverages.

The plant contains standard chemical manufacturing equipment, including reactors, compressors, pumps, tanks, and a thermal oxidizer.

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”2_3″ spacing=”” center_content=”no” hover_type=”none” link=”” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text]

Challenges

The existing control system at the plant is a mixture of DCS and PLC control schemes, integrated to allow company personnel to operate and monitor the facility. Because some of the existing equipment was designated “mature” by equipment manufacturers, the client initiated a proactive effort to upgrade controls for the B-800 Thermal Oxidizer.

The control panel for the B-800 Thermal Oxidizer contained a 90-30 PLC with a reported lack of code and variable documentation. The controls and marshalling panels contained a wire termination strategy that desperately required labeling and cleanup. In addition, the control system drawings and P&IDs were not current.

The client called on EN Engineering to increase the reliability of the B-800 Thermal Oxidizer by upgrading the controller to a platform with more capability. An HMI was added locally at the Thermal Oxidizer to display alarms and interlock statuses. The plant was shut down for two weeks for a maintenance turnaround, so the entire Thermal Oxidizer PLC upgrade had to be completed within a short time frame.

Solutions

Prior to the upgrade, EN Engineering developed a Project Execution Plan (PEP) to provide a documented comprehensive plan for the development and implementation of the B-800 Thermal Oxidizer PLC upgrade project. The two-part PEP addressed the background, objectives, scope and strategies, as well as provided a tactical plan. By following the PEP, the upgrade was completed within the challenging time frame and on budget.

During execution, a ControlLogix PLC was purchased to replace the 90-30, and a new wiring strategy was defined for installation. The existing ladder logic from the 90-30 PLC was rewritten to support the new ControlLogix platform, and a detailed data map was created for interface with the site’s DCS system. As part of installation and commissioning, the 90-30 PLC was replaced with the ControlLogix, the control panel and marshalling panels were rewired using the new strategy, the site drawings were updated as-built, and an exhaustive system test was performed. The entire project installation and cutover was successfully completed within the two-week designated downtime allotment.

“EN Engineering completed the upgrade on time and on budget. This was one of the smoothest controls projects we have experienced.” – Plant Engineer

[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]