Project Synopsis
Develop an FEL-3 process design package with Issued for design (IFD) documents, models, and calculations for a phosphate ore mining and processing facility as a sub-contractor to a detailed engineering firm.
Project Summary
Process Engineering Associates, LLC (PROCESS) was subcontracted by the client, a detailed engineering firm, to provide process design and engineering services to the ultimate client, a mining & minerals processing company, who owns and operates a phosphate ore mining and processing facility. This project involved the addition of a new ore dewatering area, containing two large filter presses and supporting auxiliary systems. Specifically, PROCESS was tasked with the development and delivery of FEL-3 Issued for design (IFD) documents, models, and calculations, based on preliminary documents provided by the client. The deliverables included:
- Piping and Instrumentation Diagrams (P&IDs) – Using a METSIM model of the new area, along with a preliminary process flow diagram provided by the client, PROCESS developed nineteen (19) original IFD level P&IDs for the new unit.
- Process Equipment Datasheets – Major equipment specifications and data sheets were developed that included two large filter presses, several tanks, vessels, agitators, pumps and heat exchangers
- Controls Narrative / Cause and Effect Matrix – PROCESS developed a process controls methodology and a cause-and-effect matrix to describe safe and reliable process automation for the new area, and to indicate how the plant DCS would interface with vendor PLC’s.
- Process Facilities Description – This document detailed the overall function, chemistry, and operation of the area and each of its major units. It described how the area would tie in and interface with the existing process. This document also specified requirements for winterization, fire protection, safety showers, maintenance access, containment, etc.
- Relief Valve Sizing. Datasheets and Supporting Calculations – PROCESS was tasked with the design and selection of relief valves where needed throughout the process.
- Instrumentation List and Design Support – PROCESS provided physical properties, materials of construction, Temperature and Pressure design specs, and operating ranges for all major area instrumentation.
- System Line List and Line Hydraulic Calculations – PROCESS performed hydraulic calculations for major piping runs, sized lines, determined materials of construction, and documented these criteria in a project line list.
Industry Type
Mining and Ore Processing
Utilized Skills
- FEL-3 detailed process design