Project Synopsis
Provide process engineer staff augmentation services as part of a plant-wide pressure relief device (PRD) revalidation project at an integrated active pharmaceutical ingredient (API) chemical manufacturing facility in the United States.
Project Summary
Process Engineering Associates, LLC (PROCESS) was contracted by a chemical manufacturer to provide staff augmentation services as part of a site-wide pressure relief device (PRD) revalidation project at their integrated active pharmaceutical ingredient (API) chemical manufacturing facility in the Southeastern United States. The client requested full-time support to evaluate many of their outstanding relief systems that had outdated or missing pressure relief information.
The project focused specifically on storage tank vents, utility system PRDs, and thermal relief valves throughout the site. PROCESS regularly traveled to the site to walk down the assigned relief systems, verify PRD models, piping isometrics, and vessel insulation thickness and materials. PROCESS also gathered required equipment datasheets and verified operating information with plant personnel.
The project spanned the entire facility and included evaluating over 600 PRDs. Various tasks were performed during the project, of which some highlights are listed below:
- Analysis of relief systems using Smith and Burgess’ SALUS software system.
- Dynamic modeling and evaluation of two-phase relief scenarios using the DIERS relief methods via CHEMCAD’s DIERS Relief Tools.
- Providing recommendations to meet recognized and generally accepted good engineering practice (RAGAGEP) requirements while minimizing required capital expenses.
- Developing relief system modifications and design packages to existing systems to meet RAGAGEP requirements.
- Mitigation of fire relief scenarios using strategies such as evaluation of tank heat up times, calculating pool fire duration, verification of insulation cladding using a handheld XRF analyzer, and quantifying reactive fire hazards.
- Advising the client on best practices of relief system design and RAGAGEP based on applicable codes and standards from ASME, API, ASHRAE, CGA, NFPA, OSHA, and internal codes and standards.
Industry Type
- Active pharmaceutical ingredient (API) manufacturing
Utilized Skills
- Pressure relief device evaluation and sizing
- On-site process engineering staff augmentation
- Dynamic process simulation modeling
- Application of RAGAGEP requirements.