Project Synopsis
Provide on-site process engineering support to a US chemicals manufacture at multiple different plant sites to support a wide variety of projects, products, and facility improvement initiatives.
Project Summary
Process Engineering Associates, LLC (PROCESS) was contracted by the client, a US chemicals manufacture, to provide on-site process engineering support across multiple different plant sites to support a wide variety of projects and facility improvement initiatives.
Facility #1
The client recently acquired a manufacturing site along the US Gulf Coast, that produces ferrous based chemicals, predominantly used in the water treatment industry. The client identified a need to redesign the process due to safety, environmental, and productivity/efficiency concerns. PROCESS was engaged by the client after the start of construction to assist by providing nearly continuous on-site project engineering and management support for approximately 6 months. PROCESS assisted the client with daily leadership and supervision of contractors, as well as identification of task and punch list items. The PROCESS engineer also reviewed the client’s heat and material balance and design basis for the new process. The client engaged PROCESS to lead a PHA for the process and provide a facilitator. The onsite PROCESS engineer participated in this PHA and then assisted with overseeing process modifications as required by the PHA findings. PROCESS worked with the client’s engineering team to specify and design the control system and interlocks (as determined in the PHA) for the new process and oversaw the testing and validation of each interlock and system. PROCESS also worked with the client’s engineering team during the start-up phase with numerous troubleshooting challenges related to mechanical and controls equipment. Concurrent to providing support for this project, PROCESS also worked with the client’s drafter to create site-wide as-built P&IDs for the facility.
PROCESS also worked with the client’s process automation team, a process automation/electrical engineering contractor, and the client’s project manager to develop preliminary design documentation for a site-wide automation campaign, to include the replacement of an existing antiquated PLC, as well as the implementation of PLC control for the new process.
Prior to the client engaging PROCESS for the work on the new process, they identified a need for an emission mitigation system on the existing process, and their engineering team worked with a technology supplier to design and purchase a demisting system. Upon installation of said system, it was determined that the technology and materials of construction were insufficient for the need, and PROCESS was engaged to provide a design and specifications for a system to meet the requirements. During the preliminary design phase, the client elected to pause the work being performed by PROCESS to instead work directly with another equipment supplier to design such a system. PROCESS was not re-engaged on this effort.
Facility #2
The client operates a manufacturing site in the western US which produces a chlorinated aluminum product in FRP reactor vessels. The resin lining inside the vessels naturally wears over time due to abrasion and chemical corrosion. Therefore, the site traditionally engages a contractor to re-line 2-3 reactors annually. PROCESS was engaged to provide project management for the re-lining effort of the vessels and worked with the client’s preferred FRP repair contractor to obtain quotes for repair. PROCESS then completed the client’s AFE (approval for expenditure) process to secure funds for the annual repairs. Following approval, PROCESS coordinated with the site and contractor to schedule the repairs. A PROCESS engineer traveled to the site for approximately 1 week for the repair kick-off and to observe and oversee the repairs to one of the three vessels that were re-lined. Following the trip, the PROCESS engineer continued to communicate with the repair contractor to ensure the timely and successful completion of the project. The PROCESS engineer also submitted frequent project status updates to the client’s plant and regional management team.
PROCESS engineer was subsequently re-engaged to assist at this site with process engineering, operations, and oversight tasks following the departure of the plant manager. The PROCESS engineer traveled to the site for one week to review the process and operations with one of the client’s senior engineers. The PROCESS engineer will be returning to provide additional on-site support.
Facility #3
The client operates a manufacturing facility in the central US that produces aluminum based water treatment chemicals. The client had recently completed a project to install a system for producing a low-iron aqueous aluminum chloride product using ion exchange resin beds but was unable to produce in-specification product using the new system. PROCESS was engaged to provide on-site support to conduct bench scale testing with ion exchange resins to troubleshoot and develop an operational procedure to produce in-specification material with this new equipment. The PROCESS engineer also redesigned the layout of the flow manifold for the two resin beds used in the system to improve operational efficiency and simplicity and oversaw the implementation of the new design by a mechanical contractor. Finally, PROCESS authored operational procedures for the system and provided training to the lead operator for the process.
While at the site, PROCESS also provided support with design and implementation of modifications to the aluminum chloride process to improve heat stability of the product. This included reviewing existing P&IDs for the process for accuracy and making design modifications. PROCESS worked with the client’s project manager to develop a scope and obtain quotes for the modifications. The PROCESS engineer also participated in a PHA facilitated by the client and then worked with the client to implement the findings into the design. Following project development, the PROCESS engineer provided engineering support throughout the construction phase and assisted with system start-up and process documentation, including authoring operational procedures, and providing operator training.
Simultaneously, the client also identified a need to repair the concrete floor in a process building, which had begun to buckle significantly over time. The client’s project manager engaged the PROCESS engineer to assist with on-site coordination with a civil/structural engineering contractor to develop a repair plan, which also included the addition of chemical containment to the building. The PROCESS engineer reviewed the process as-build P&ID and red-lined it for accuracy. Demo and design drawings were then completed in coordination with the client’s drafter for the replacement and re-piping of the reactor discharge pump (the piping to and from which was impacted by the buckling floor), the process and safety shower water systems in the building, and the acid line from the rail unloading area into the top of the reactor. These drawings were then used as part of a client facilitated PHA, in which the PROCESS engineer participated. The PROCESS engineer then incorporated findings from the PHA into the design, and worked with the client’s project manager to specify and quote all components of the design. The PROCESS engineer continues to provide remote and on-site support throughout the project, which is currently on-going.
While on-site, the PROCESS engineer was also asked to review the cooling system for the plant’s Pressure PAC process, and issue recommendations for decreasing the required batch cooling time. The PROCESS engineer walked-down the system and reviewed current operations with process operators and collected instrument data on system parameters. Cooling load calculations were then performed, and a report was issued with recommendations.
Industry Type
Water Treatment Chemicals Manufacturing
Utilized Skills
- On-site process engineering support
- Capital project scoping
- Project engineering support
- Process improvement support.