Plant Expansion in Phases

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Project

Plant Expansion – Petroleum Product Packaging
Location

Texas

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Background

A petroleum product packaging client requested a plant expansion, impacting 62,000 square feet of their existing property. The total area impacted required demolition of existing assets, grading reconstruction, underground piping modifications, and the installation of three new buildings. The buildings included a pallet storage building (8,000 sf) with a mezzanine and underhung crane, a 3,800 square-foot canopy area, and a production plant expansion (12,800 sf) with loading docks.

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Challenges

The client’s property is landlocked and congested with truck traffic, which necessitated a design to accommodate construction in phases. The property drainage was dependent upon underground infrastructure at the adjacent property, which required coordination in the design and construction. The design of the production plant expansion required intense coordination with the building vendor and contractor. There were multiple issues with marrying the new building to the existing that required extraordinary engineering considerations.

Solutions

An EN Engineering team was dedicated to the project, with a Senior Project Manager as the single point of contact, a request made by the client. Initially EN Engineering subcontracted with a geotechnical firm to verify the site conditions, and completed a 3D scan of the site. EN Engineering worked with plant operations to develop a feasible plan for the phasing of construction. In coordination with a pre-engineered building vendor, EN Engineering developed a detailed design package for the complete plant expansion. The project, which tallied more than 2,000 man hours, was efficiently supported by staff from EN Engineering offices in League City, TX and Catlettsburg, KY.

“The design of the production plant expansion required intense coordination with the building vendor and construction in phases.”

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Sample Stations Designed and Installed to Resolve Deficiencies

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Project

System design, procurement and construction support for sample stations

Location

Texas

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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.

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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.”

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Fall Protection Hazards Mitigated to Enhance Safety

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Project

Platform Upgrade for Fall Hazard Remediation

Location

Catlettsburg, KY

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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.

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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.”

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PSI Validation Instills Confidence

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Project

PSI Validation of Refinery Relief System
Location

Marathon Petroleum Company
Catlettsburg, KY

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Background

The client, one of the country’s largest crude oil refineries, called on EN Engineering to validate the PSI components of their relief system, including development of process diagrams, isometric drawings, design specification sheets, and associated equipment file items.

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Challenges

The project presented a number of interesting challenges. First, the overall size and scale of the project was enormous, covering every unit in the refinery. In addition, the team had to deal with the demolition of equipment in several units, which impacted the relief paths.

Solutions

The project required field verification of all process diagrams and isometric drawings representing the flare, atmospheric, and process/thermal components of the client’s relief system. EN Engineering developed a tracking spreadsheet to ensure that all required information was gathered during the field verification and reviewed it against the information found in the multiple refinery information storage systems for master PSI and equipment documentation.

All of the required revisions were tracked across the multiple refinery information storage systems, and the systems were audited to confirm the proper documentation had been linked and correctly illustrated the project revisions. The PSI validation and equipment documentation assured the client that the relief system PSI and equipment documentation were correct and the information can be used with confidence in the future.

“The PSI validation assured the client that the relief system PSI and equipment documentation were correct and the information can be used with confidence in the future.”

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PSI Audit Identifies Compliance and Offers Focused Guidance

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Project

PSI Audit Identifies Compliance and Offers Focused Guidance

 

Location

Kentucky

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Background

Our client, one of the country’s largest refineries, requested that EN Engineering perform a Process Safety Information audit for their FCC unit.

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Challenges

This audit had to comply with the requirements of the Refinery PSI Standard Practices. The request for proposal identified the following elements which were audited during this process:

  • Plot plan drawings
  • Process flow diagrams
  • Electrical area classifications
  • Equipment files/Instrument data sheets
  • Equipment files/Relief valve data sheets
  • Equipment files/Fixed and rotating equipment
  • Material and energy balances
  • Ventilation system design data
  • Occupied buildings ventilation system design data
  • Pressurized/purged enclosures

Solutions

EN Engineering assembled an expert team of PSI professionals. The team consisted of an audit leader, two P&ID walk-down staff, one Electrical & Instrumentation engineer, and one staff member reviewing M&E balance information.

The objective of the audit was to identify compliance status with the selected PSI elements and to provide focused guidance to upgrade the level of compliance of the Process Safety Information program. These PSI audits are in alignment with the facility PHA standard that requires PSI to be evaluated and updated prior to submitting PSI records to the PHA team in advance of the actual PHA start date.

The EN Engineering team is a critical part of our PSI Program. Their experience and expertise support our PSI efforts, and they provide high-quality work for the refinery.

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