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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Submersible Transformer Replacements Provide Improved Access and Reliability

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Project

Submersible Transformer Replacement Program

Location

Ohio/Kentucky

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Background

The client wanted to eliminate all submersible transformers on their distribution system to allow improved access to equipment and replace aged equipment. A total of 500 underground facilities were to be converted to above ground pad-mounts. EN Engineering replaced all primary and secondary cables, along with the terminal poles associated with these locations.

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Challenges

This program took place in upscale, older neighborhoods that were unaccustomed to seeing traditional pad-mount transformers. It was critical to educate customers on the improvement in reliability associated with the new transformers and to work closely with the customer and county to select transformer locations that would minimize visual intrusion while maintaining the electrical improvements desired. In addition, the project provided the opportunity to evaluate and identify looping and reliability opportunities for these neighborhoods.

Solutions

EN Engineering independently ran this new program and provided critical client communication. The team was responsible for planning, detailed design, cost estimating, permit package preparation, easement research, acquisition identification and construction support. More than 250 transformers and 25 miles worth of cabling were targeted for replacement over the course of a three-year construction cycle. The primary, secondary and associated service cabling was also replaced and additional looping was targeted. Our designers were responsible for doing the scoping, detailed design and construction support for all sites associated with these replacements.

It was critical to educate customers on the improvement in reliability and safety associated with the new transformers.

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TDSIC Electrical Distribution Filing Helps Client Secure Funding

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Project

TDSIC Filing Design and Cost Estimate Support

Location

Evansville, Indiana

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Background

The client required assistance with design work related to their TDSIC grid modernization rate case filing. The project included scoping/planning, field survey, detailed design, cost estimating, permitting, and construction support for multiple types of overhead and underground projects.

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Challenges

EN Engineering had to quickly assemble a team of 40 professionals to execute a high-volume project within an aggressive schedule of a five-month period that required more than 200 detailed designs and over 600 cost estimates.

Solutions

EN Engineering completed detailed designs and cost estimates associated with the client’s Energy Grid Modernization Filing with the IURC. The team completed preliminary engineering, field data collection, detailed design, project management, and complete project controls for all distribution jobs associated with the filing. The detailed design included drawings, permit packages, cost estimates, pole loading analyses, work order creation, and ESRI GIS updating. Over five months, 200 detailed design projects and 600 cost estimates were completed. The filing helped the client secure $500,000,000 in funding for grid modernization projects over the next five years. This success was due to EN Engineering’s critical focus on training and understanding of the client’s internal systems and standards.

Over five months, 200 detailed design projects and 600 cost estimates were completed.

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Complex Export Terminal Control System Installation Made Easy

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Project

Export Terminal Control System Installation

Location

Houston, Texas

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Background

One of the largest energy infrastructure companies in North America needed to build a new terminal on the Houston Shipping Channel to export gasoline, naptha, and diesel fuel directly into large maritime vessels.

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Challenges

The terminal was a brand new facility, integrating 12 large tanks (1.5M barrel capacity), 16 pumps, 200 motor operated valves, 150 measurement instruments, and 4 vapor recovery systems. The facility also had barge and ship docks to facilitate vesselloading operations on the shipping channel. The export terminal was to be completely automated and controlled from the control room across the channel. This meant that all indicators, controls, and alarms would need to be accessible remotely. Because the existing control system was built on technology from previous decades, the new export terminal control system needed to remain compatible with both old and new technologies.

Solutions

A project execution plan and project schedule were created prior to the control system design. The EN Engineering team was embedded with client resources to operate in a unified manner. PLC, network, and computer hardware were chosen that precisely followed the client’s standards and compatibility with past/future systems.

Rigorous testing was performed with strict adherence to ISO standards, and frequent checkout documentation audits were completed.

At installation, the benefits of the testing efforts were realized. Only 50 percent of the expected travel to the job site was required, as the client was able to install much of the system without assistance. In addition, the final list of desired modifications after installation was minimal. The project was completed on schedule and under budget. More importantly, the client was happy and placed EN Engineering on bid lists for other projects in Texas and Louisiana.

The EN Engineering team was embedded with client resources to operate in a unified manner.

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Automation Upgrades for Improved Control and Monitoring

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Project

Compressor Station Control
System Automation Upgrades

Location

Springville, New York

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Background

The client’s compressor station consisted of five Cooper GMVH-10C2 compressor units (total station HP of 11,250). The client received approval to increase capacity to transport Pennsylvania-produced Marcellus Shale gas to the TransCanada Pipeline in western New York. The client required piping modifications and horsepower additions to allow the fuel gas to flow north.

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Challenges

The existing systems were a mixture of mature PLC control equipment and hardwired control schemes, and the facility was operated manually by operators. The design specs called for a fully-automatic system with remote monitoring and control. Existing hardware and end devices were unreliable, so new devices were required to allow for safe automatic control. New equipment and instrumentation were required for the piping modifications and capacity increase, which required electrical installation services. A solar turbine control system had to be integrated into the new station control system to allow for automatic control and monitoring from NFG Gas Control.

Solutions

EN Engineering developed a controls design specification and electrical scope of work for implementation of the controls upgrade project, and provided engineering design, project management, drafting, programming, commissioning, and training services to guarantee stable and safe operation of the station, engine/compressors, and auxiliary equipment.

EN Engineering also supplied all of the necessary engineering, design, hardware, fabrication, software, and project management for five unit control panels, the station control panel, and three remote I/O panels. Complete drawing sets and documentation were provided to the client for factory acceptance testing of all panels and software prior to shipment for installation. In addition, EN Engineering provided engineering design services for the electrical installation of the controls upgrade project. Electrical equipment layout drawings, electrical details, schematics, and conduit and cable schedules were provided showing terminations and interconnection of new and existing I/O with the new control panels.

During the project, EN Engineering coordinated and managed the electrical installation and commissioning of the station and unit control systems. As part of the installation, individual systems were removed from service for a short duration, and upon completion, a commissioning team tested and calibrated the new equipment. An on-site acceptance test and startup was performed with the client prior to putting each station and unit control system into service. The entire project installation and cutover was successfully completed within the designated downtime allotment.

EN Engineering provided engineering design, project management, drafting, programming, commissioning, and training services to guarantee stable and safe operation of the station.

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Design, Demolition, and Installation of Replacement Flare Stacks

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Project

Design, Demolition, and Installation of Replacement Flare Stacks

 

Location

Kentucky

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Background

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

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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

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Detailed Design for Replacement Electrical Substation

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Project

Detailed Design for Replacement Electrical Substation

 

Location

St. Paul, Minnesota

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Background

EN Engineering was contracted to prepare a detailed engineering design package for the installation of a replacement 480V electrical substation within a petroleum refinery.

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Challenges

To alleviate service disruption, construction of the new substation was to be completed without interruption to the existing plant operations. In addition, final electrical tie-ins and commissioning activities had to be completed during a previously planned unit outage.

Solutions

EN Engineering developed a detailed installation plan to allow for budgeting and construction over a two-year period. Design elements included the design of the foundation and structural steel to support the new substation, cable tray layout and design, cable sizing, coordination study, and protection device. The project also included preparation of Requests for Quotations to purchase the substation equipment, bid evaluation, bills of material, construction schedules, scopes of work, and cost estimates. The project was completed on time and on budget, providing the client increased electrical capacity, safer operations, and increased reliability.

The project was completed on time and on budget, providing the client increased electrical capacity, safer operations, and increased reliability.

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Ohio Accelerated Main Replacement Program

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Project

Ohio Accelerated Main Replacement Program

 

Location

Cincinnati, Ohio

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Background

Our client, a large gas energy holding company, enlisted the services of EN Engineering to undertake a long-term, large-scale main replacement program in its Ohio service territory in order to improve the reliability, efficiency, and safety of their gas distribution system.

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Challenges

The long-term project included field noting to build a base map of existing conditions, and the creation of construction drawings that illustrated tie-ins and line of lay for the new gas mains.  Many of the replacements were in congested urban areas with a large number of existing utilities, which created design challenges.

Solutions

As part of an Accelerated Main Replacement Program (AMRP), the client replaced nearly 1,200 miles of 12-inch and smaller cast iron/bare steel gas main over 15 years. EN Engineering worked on the AMRP from 2007 through 2015, successfully completing the design and permitting for more than 400 miles within the aggressive schedule.

Each year throughout the project, the client requested that EN Engineering design additional footage based on the valuable experience, dependability, and the high quality work product provided. In addition, due to new efficiencies created by the team, EN Engineering dropped its fixed fee prices each year.

Based on the success of this program, EN Engineering earned a multi-year contract to submit permit applications for the renewal of 60,000 services throughout the client’s Ohio and Kentucky service territories as part of their Accelerated Service Replacement Program (ASRP) over the next ten years.

Within an extremely aggressive time frame, EN Engineering successfully completed the design and permitting of more than 400 miles of main replacement.

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