Multi-Discipline Engineering for Revolutionary Demonstration Plant

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Project

PureCycle Feedstock Evaluation Unit (FEU)

Location

Irontown, Ohio

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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.

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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”

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Seamless Service for Successful Station Upgrade

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Project

Manor Gate Station Upgrade

Location

Maryland

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Background

Baltimore Gas & Electric (BGE), the company that operates the entire Baltimore area gas distribution system and serves more than 650,000 customers, contracted EN Engineering to upgrade their existing Manor Gate legacy station. This station takes the transmission gas from TransCanada at 720 PSIG and lowers the pressure to 269 PSIG to feed BGE’s Beaver Dam and Notch Clift transmission lines.

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Challenges

The original BGE drawing showed 16” steel, but the pipe was 24”, so the spherical tee that was ordered for 16” did not work. A custom-made tee was ordered, which resulted in a 14-week delay. In addition, commissioning was delayed due to the frigid ambient temperature and weather forecast.

Solutions

The Manor Gate Station upgrade project included two meter runs, four regulator runs, a separator/filter, heater, odorization, controls, and fire suppression, in addition to considerable construction of buildings and concrete to house this equipment. EN Engineering took the design work from conception through completion and also provided the environmental and construction materials testing, resulting in time and cost efficiencies. The team developed accurate and detailed as-built drawings, which required minimal field changes. The construction management team was on site and eliminated time lapses for design questions during construction. Throughout the project, they focused on jobsite safety, contractor oversight, adherence to BGE standards, and cathodic protection. In addition, they interfaced with the compliance team, Certified Weld Inspector, and NACE coating inspection. Weekly meetings with the client’s senior management team assured the project was on track, and the EN Engineering team’s expertise was welcome and respected.

“EN Engineering took the design work from conception through final design and also provided the environmental and construction materials testing, resulting in time and cost efficiencies.”

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Multiple Product Areas Join Forces on Pipeline Project

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Project

New Pipeline and Injection Facilities

Location

Texas

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Background

A new midstream energy company called on EN Engineering for a wide array of services supporting a new pipeline system and injection facilities.

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Challenges

As a new company, the client had not yet developed comprehensive project procedures, so one challenge involved working together to establish new processes and standards. In addition, the project had an aggressive timeline and required the team to work at an accelerated pace.

Solutions

EN Engineering provided project management, engineering, and design services for a new pipeline system consisting of more than 70 miles of 8” and 12” diameter pipeline, as well as five new injection facilities for multiple third-party producers.

Experts from EN Engineering’s entire service portfolio came together to successfully complete the project. The pipeline design team provided oversite of the pipeline routing as well as development of engineering design details, while a facility team provided full mechanical, electrical, civil, and structural design packages, along with hydraulic and surge analysis.

Environmental experts oversaw an environmental survey and provided recommendations for both compliance measures and installation best practices along the pipeline. Several scenarios for flow modeling were evaluated by the integrity team, who also provided recommendations for emergency flow restricting device (EFRD) valves. GIS services were utilized to evaluate alternate pipeline routes and make a commercial recommendation. Designs for cathodic protection were provided by the corrosion team. Finally, procurement experts provided comprehensive support on all equipment, material, and labor contracts, from specification development to expediting and tracking deliveries.

EN Engineering also provided several specialty services, including in-house HAZOP facilitation and shop inspection services, and managed geotechnical, environmental survey, and mill inspection subcontractors. The automation team developed the control philosophy for the injection facilities and interfaced with third-party programmers and PLC integrators.

The EN Engineering team was instrumental in guiding industry best practices and helping the client develop new procedures and standardizations. In addition, they facilitated communications despite several changes in client stakeholders at critical stages during front-end loading and worked at an accelerated pace to meet project deadlines.

“Experts from EN Engineering’s entire service portfolio came together to successfully complete the project.”

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Site Assessment Saves Time and Money

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Project

Site Assessment and Interconnection Support for Utility-Scale Renewable Energy Project

Location

Maryland

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Background

A Maryland-based developer of renewable energy projects was developing a solar generation project and contacted EN Engineering to assess the project site and provide interconnection support. The project team had to determine the project’s optimal size, identify possible points of interconnection to the transmission grid, assess the project’s impact on the transmission system, estimate interconnection and system improvement costs, and assist in producing the designs, transmission system studies, calculations, and documentation required to determine the project’s viability.

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Challenges

The team encountered difficulties obtaining information on the progress of a previously-filed project in the vicinity which would impact capacity. They searched records of public projects at the local and state levels and discovered that the other project failed to secure environmental permits and withdrew. In addition, the client had less than five days left on the Independent System Operator’s schedule to file the application, requiring the EN Engineering team to work extended hours and capitalize on previous experience to produce a deficiency-free application in three days.

Solutions

The EN Engineering team researched multiple sources to determine available Points of Interconnection (POI) options available for the utility-scale solar energy project site and investigated the suitability of each identified POI for the size of the project being proposed. They also researched other proposed generation projects in the same geographical area and potential issues that could impact the project. The team’s extensive knowledge of the various local, state, federal, and regional agencies enabled them to efficiently research and identify proposed projects. The project team filed deficiency-free applications to determine the ISO class and met strict deadlines for ISO class closing dates, using their extensive experience assembling filing packages and flexibility in scheduling the work hours.

EN Engineering modeled the transmission system at the desired size and connected at the POIs. They identified the optimum size from a system improvement perspective and estimated costs. Based on the client’s direction, they prepared and produced all documentation, calculations, studies and drawings required to file the interconnection application. In addition, they reviewed feasibility, system impact and facilities study reports and conducted load-flow studies to verify the accuracy of the ISO studies.

EN Engineering identified an incorrectly assigned improvement charge in the ISO-generated studies that would have cost the client $22M in interconnection fees. In addition, the client was able to save time and effort by focusing on those sites where interconnection costs made the projects economically viable.

“EN Engineering identified mistakes in the ISO-generated studies that could have cost the client $22M.”

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Advanced Metering Infrastructure Modernization

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Project

AMI Communication Network Design

Location

Southwest Indiana

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Background

Our client, a major provider of electrical and gas services in Indiana, was expanding their Data Transmission Network by adding connected grid routers (CGRs) to their poles and requested assistance designing the new pole locations.

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Challenges

One of the installation locations placed the pole in a customer’s front yard, and they called to complain and request relocation. In addition, the client’s project team changed mid-way through the project.

Solutions

EN Engineering provided design services to help a client expand their data transmission network. The project team surveyed and designed 41 connected grid routers (CGRs) on utility poles. Since the client was adding poles outside for their electric service territory, EN Engineering served as the interface between the client and three different electric utilities to secure permits and new power drops. After surveying the route to determine appropriate locations for the CGRs, the team used GPS technology to identify and map the installation locations. Designs for each CGR were created, and the team worked to obtain right of way, city/county permits, and identify the utility company that would supply service to each location.

The team worked with the unhappy residential customer to resolve the problematic pole installation location and ensured they were satisfied with the new location. In addition, the client’s team changed mid-way through the project, so the EN Engineering team met with the new staff and provided a detailed briefing to bring them up to speed and alleviate any potential delays.

“The EN Engineering team mitigated the potentially long lead time by making adjustments to the scope.”

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Smart Grid Reliability Enhancements

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Project

Electric Distribution Smart Grid Upgrades

Location

Maryland

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Background

Our client, the owner and operator of the gas and electric infrastructure in the Baltimore metropolitan area, called on EN Engineering to assist with a large electric distribution upgrade project and provide design services for storm hardening with the assistance of Smart Grid technology.

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Challenges

The proposed plan required overhead structures to be installed in a county park, which would have delayed the construction due to permit issues. In addition, a rare tree was rooted in the area, so a workaround had to be designed.

Solutions

EN Engineering provided design services for storm hardening to reduce supervisory control and data acquisition (SCADA) on outages, including the installation of Smart Grid technology to 40 poles of overhead electric cable and 5,090 linear feet of underground electric cable. This included an overhead recloser, fuse coordination, re-conductoring to Hendrix spacer cable, and pad-mounted equipment. The EN Engineering team prepared construction prints, communicated with the client’s project manager and engineer, conducted quality assurance/quality control reviews, and submitted all required permit application documents.

To resolve the issue of overhead structures in a county park, the team mitigated the potentially long lead time by making adjustments to the scope. The revised plan met the requirements of the client’s engineer and reused existing overhead structures to avoid work within the county park property. In addition, they avoided negative impact to a rare tree by using poles owned by a communication company.

The EN Engineering team provided technical support throughout the construction procurement process and communicated with the client’s customers and local government departments to keep all stakeholders apprised of the project’s progress. The project was completed in 2017 without any issues, on time, and on budget. Since then, seven additional projects of similar scope have been completed successfully. The client has demonstrated their confidence in the team’s communication, quality, timeliness, and ability to mitigate design and construction issues by rewarding EN Engineering with additional design projects.

“The EN Engineering team mitigated the potentially long lead time by making adjustments to the scope.”

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Self-Optimized Grid Improvement

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Project

Recloser Design for Self-Healing Networks

Location

Cincinnati, Ohio

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Background

One of the largest electric power holding companies in the U.S. is undertaking an initiative to upgrade systems across their service area to implement Smart Grid technology. They are building self-healing networks to help isolate outages and reinstate power more quickly for customers who are outside of the problem area. They enlisted EN Engineering to design reclosers to replace manual switches on the networks.

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Challenges

Once in the field, the team encountered constructability issues between the master plan and a few of the construction locations.

Solutions

After the client identified locations on their network for recloser placements, the EN Engineering team inspected the pole locations to determine their accessibility, condition, and clearance. They worked with the client to resolve location issues for several poles and recommended alternative locations. To resolve constructability issues, the team identified problematic poles, provided the client with options for more optimal locations, and successfully relocated the poles. Finally, the team developed construction drawings and estimates for labor and materials for each recloser.

Over the next two years, EN Engineering will design more than 200 reclosers in the Cincinnati region. The team effectively manages the demanding workflow and communication with the client by maintaining a detailed spreadsheet and sharing it with the client weekly. The EN Engineering team’s knowledge and experience with Smart Grid technology contributed to the success of the project and has led to expansion in other regions of the country. EN Engineering is now providing recloser design services for the client’s North Carolina service areas.

“The EN Engineering team’s knowledge and experience with Smart Grid technology contributed to the success of the project.”

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Engine Retrofit Reduces Compressor Station Emissions

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Project

Engine Emissions Optimization Retrofit

Location

Central Pennsylvania

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Background

The client, one of the country’s leading energy providers, called on EN Engineering to provide engineering design services to support the installation of an engine emissions optimization retrofit with the goal of reducing emissions at their compressor station.

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Challenges

Congested below-grade piping was located via a subsurface survey of the area identified for installation of major equipment, and due to existing site layout constraints, the equipment could not be installed in any other area. In addition, because of weather issues, the team was unable to access detailed soil analyses and encountered shallow rock. Finally, due to incomplete historical records, the team was unable to access a full register of existing system air demands.

Solutions

EN Engineering provided engineering design services to support the installation of an engine emissions optimization retrofit for one Cooper-Bessemer GMVA-8 recip and all ancillary equipment. In order to support this installation, various auxiliary systems underwent upgrades, including the fuel gas and compressed air systems, and a new auxiliary water cooling system was installed. The project required design of various foundations and replacement of an existing motor control center in addition to the fuel gas, water, and air system upgrades.

Because the team could not access detailed soil analyses, the foundation designs required revisions. The team reviewed past projects and used engineering judgment to devise foundation designs that were conservative yet not over engineered.

In addition, an existing air system analysis was completed based on limited information and input from station personnel because the team could not access a full register of existing air system demands. Using past projects and engineering judgement, the team revised the existing system analysis until it matched the existing operating conditions described by station personnel. This analysis was used as an accurate baseline for additions due to the requirement for completion of a full air system sizing evaluation.

The team compared existing drawings to subsurface investigation results obtained via ground penetrating radar to determine the locations and services of the buried lines, then worked with the client to identify which below grade lines could be relocated or retired, adjusting the equipment locations within the constraints to avoid those below grade lines that could not be disturbed. Despite these challenges, the installation was completed successfully and compressor station emissions were reduced.

“The project required design of various foundations and replacement of an existing motor control center.”

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Powering Up the First U.S. Offshore Wind Farm

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Project

Offshore Wind Generation

Location

Rhode Island

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Background

EN Engineering was called on to provide project management, owner’s engineer, and outage planning services for the first commercial offshore wind farm in the United States, located three miles off the shore of Rhode Island. Construction of the five turbine, 30-million-watt project began in 2015, and in late summer 2016 five Alstom Haliade 150-6-MW turbines were erected. The project interconnects to the client’s 34.5 kV sub-transmission system and supplies power to Block Island and the mainland. Our client is the interconnecting utility and the owner/operator of the facilities.

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Challenges

Because there were no precedents for this type of project, challenges included gaining new experience with permitting, constructing, and commissioning. In addition, EN Engineering facilitated communication among all of the stakeholders, including state and federal authorities. Finally, several severe weather events impacted the timeline of the project.

Solutions

EN Engineering worked with the client to design substations on the island and mainland, modify a third substation to receive the output of the project, install 13 miles of submarine cable from the island to the mainland, and install an additional five miles of underground cable to connect to the transmission grid. The EN Engineering team provided overall coordination of construction schedules between the client and other entities and also facilitated communication between parties. In addition, the team developed outage management and energization plans and schedules, developed switching protocol for the 34.5 kV cable system, and reviewed equipment and cable specifications. Effort was made to obtain additional temporary workspace where available to allow the contractors flexibility in construction for safety and cost effectiveness. The challenging 6-month project was completed on time and on budget.

“EN Engineering provided project management, outage planning services, and served as owner’s engineer for the first commercial offshore wind farm in the United States.”

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Successful Upgrade of Water Infrastructure

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Project

Water Main Upgrade

Location

Upper Darby, PA

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Background

The client, a leading provider of water and wastewater utility services in Pennsylvania, is currently investing over $450 million to replace and improve their water and wastewater infrastructure. They called on EN Engineering to replace a large, existing cast iron water main with ductile iron.

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Challenges

The replacement took place along a road with storm drain culvert crossings, which required detailed calculations and analysis. In addition, the road is heavily traveled and highly congested, which made field noting more difficult than usual.

Solutions

EN Engineering designed construction plans and coordinated environmental permitting for the project, which replaced the existing cast iron water main along the busy road. The replacement included approximately 7,650 feet of 8” ductile iron water main and took place along a road with two large storm drain culvert crossings, which required horizontal directional drill path calculations, analysis, and profiles. Because the road is a major transportation artery, field noting was particularly challenging.

The project was completed successfully, and the client relationship continues to expand. EN Engineering is now helping coordinate design and construction plans for future projects between the client and the local gas provider.

“The replacement took place along a road with two large storm drain culvert crossings, which required horizontal directional drill path calculations, analysis, and profiles.”

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