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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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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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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Pipeline Replacement Through Existing Gas Corridor

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Project

Dubuque Pipeline Replacement
Location

Northern Illinois

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Background

A large natural gas distribution company required detailed engineering and design for a 30-inch, 8-mile pipeline replacement project located in northern Illinois.

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Challenges

The project posed a number of challenges. First, the pipeline was routed through an existing gas corridor in a heavily populated area. In addition, the existing 22” pipeline was replaced with a 30” pipeline, so a workaround had to be designed to accommodate this change.

Solutions

Because the pipeline was in a heavily populated area, the team worked closely with the client’s real estate group to ensure all landowner concerns were mitigated prior to construction. Additionally, proposed pipeline installation methods were adjusted to place equipment in less populated areas. The proposed pipeline was to be installed mainly within the existing local gas distribution company’s easement.

To accommodate the new 30” pipeline, the design had to take into account the existing 22” pipeline that was required to stay in service throughout construction. The designers developed a way to locate the proposed 30” pipeline within the existing easement. The replacement required precision locating by the survey and subsurface utility consultants to ensure the existing pipeline was accurately located both horizontally and vertically. Once the designers received this information, locating the proposed 30” pipeline in the easement was crucial to maintain sufficient clearances between the existing 22” pipeline and other third party utilities, while still maintaining the construction limits within the existing easement. Every 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.

“The replacement project required precision locating by the survey and subsurface utility consultants to ensure the existing pipeline was accurately located both horizontally and vertically.”

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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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