Process Plus Completes Chemical Process Scale-Up

Process Plus completed the Conceptual, Definition, Detail Design, Procurement, Automation, Construction Management, Process Safety Hazard Analysis and Management, and Commissioning for the expansion of an existing pilot scale process utilizing flammable liquids. The project included the renovation of an existing building to accommodate a new production suite and the installation of an outdoor tank farm. This facility is PSM regulated.

Total Project Capital: In excess of $8 Million

Start Date: April 2010

Status: In Startup

System Includes:

• Below Grade Storage Tank Farm
• Containment Vault
• Solvent Storage and Facility Ventilation
• Dust and Vapor Collection
• Chilled and Tempered Water Systems
• Nitrogen Generation System
• Centrifuge Installation
• Reaction / Dispersion / Milling Operations
• Tote Unloading and Drum Filling Systems
• Material Storage and Cooler Rooms
• ASI and FieldBus Foundation Systems
• Emergency Generator
• Motor Control Centers
• Safety and Process PLC’s

Services Provided:

• Process Engineering & Design
• Process Hazard Analysis (PHA)
• Mechanical Engineering
• Instrumentation & Controls
• Automation
• Civil/Structural Engineering
• Architectural
• Concrete Foundation & Masonry
• Fire Protection Performance Spec
• Electrical Engineering & Design
• Cost Estimating
• Procurement
• Construction Management
• Commissioning and Startup

Value Provided by Process Plus:

• Utilized 3D CAD for design, which allowed client personnel to
  “walkthrough” the facility ahead of time. Doing so, the client was given
  the opportunity to make adjustments prior to construction saving the
  client construction costs.
• With over 1000 items purchased for this project, Process Plus provided extensive procurement support by evaluating vendor equipment bids, providing recommendations, preparing purchase requirements, and expediting all orders to meet aggressive schedule demands.
• Provided PLC programming, prepared operator screens and sequence diagrams and performed client acceptance testing (CAT). Complete the
  CAT allowed the client to make minor adjustments prior to downloading changes onto the client’s PLC programming system, preventing greater
  time and cost expenses.
• Completed construction quality assurance and quality control minimizing construction costs by addressing concerns prior construction
  completion.
• Initiated PSM program and provided all personnel with general awareness training. Client had no previous PSM experience or expertise to complete
  this project to the necessary safety standards.
• Saved client time by incorporating safe practices throughout design.
• Initiated requests to test materials during design to determine range
  of material property hazards preventing greater costs and schedule implications during construction.
• Performed installation checks for all equipment and instrumentation.
  Static checks allowed Process Plus to verify specifications were met preventing possible cost implications and safety issues.
• Completed operation commissioning to examine heating and cooling to
  obtain temperature profile which lead to fine tuning of programming prior
  to startup.