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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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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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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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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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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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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Compressor Station Control Panels Designed, Programmed, and Commissioned with Limited Timeline

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Project

Gibson Compressor Station

Location

Pennsylvania

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Background

The client, a large energy company with assets across the United States, tasked EN Engineering with designing and fabricating their Gibson Compressor station control panels, programming the station’s logic controllers and operator interface, and assisting with the installation and commissioning at the facility. The Gibson Compressor station was designed and constructed in 2013-2014 and is part of a gathering system in Eastern Pennsylvania that conditions and compresses natural gas from local wellheads so it can be delivered to interstate pipelines.

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Challenges

With a limited timeline to complete the design, EN Engineering had to diligently maintain a demanding project schedule to ensure timely project delivery.

Solutions

The EN Engineering team completed a detailed design package for the station control panels, procured all equipment for the control panels, and oversaw the panel fabrication process. In addition, EN Engineering completed the programming for the two programmable logic controllers responsible for maintaining the safe operation of the station and programmed the operator interface system to allow the station operator to monitor and control the facility from the control room. The team also provided on-site commissioning support to verify the functionality of all station instrumentation and control systems and assisted with the startup of the station and compressor units.

“With a limited timeline to complete the design, EN Engineering had to diligently maintain a demanding project schedule to ensure timely project delivery.”

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Engineering and Environmental Design for Large Warehouse

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Project

Engineering and Environmental Design for Large Warehouse

 

Location

Harford Country, Maryland

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Background

EN Engineering provided engineering and environmental design resources to successfully obtain all approvals allowing construction of a 600,000+ square foot cross-dock warehouse distribution center.

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Challenges

The client called on EN Engineering to provide environmental design to meet stormwater requirements while also maximizing the building size.

Solutions

EN Engineering’s efficient environmental design allowed the client to maximize the useable area while avoiding and minimizing environmental constraints. The design included creative site work that met stormwater quantity and quality management requirements for a significant amount of impervious surfaces, while maximizing the building size, loading docks and truck/trailer storage. The 600,000 square foot facility includes a cross-dock warehouse, truck/trailer parking, storage and docking, employee parking, and administrative access.  The project involved successful abandonment of a County Road/ROW, offsite reforestation involving Harford County Parks and Recreation and plan adjustments as potential tenants were negotiating lease options with our client. EN Engineering also coordinated the legal, architectural, county and state approvals.

EN Engineering’s efficient environmental design allowed the client to maximize the useable area while avoiding and minimizing environmental constraints.

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Landfill Closure Meets Environmental Compliance Regulations

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Project

Landfill Closure for Steel Facility

 

Location

Ashland, Kentucky

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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.

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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.

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Evaluation and Installation of Stormwater Management System

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Project

Evaluation and Installation of Stormwater Management System

 

Location

Haverhill, Ohio

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Background

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

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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.

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