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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PSI Audit Identifies Compliance and Offers Focused Guidance

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Project

PSI Audit Identifies Compliance and Offers Focused Guidance

 

Location

Kentucky

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Background

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

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Challenges

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

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

Solutions

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

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

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

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