Case Study
Batch Production Facility – Detail Engineering
Challenge:
A titanium producer wanted to revamp their existing continuous facility to build a batch production facility based on their existing pilot plant technology. The client wanted to reuse some of the existing equipment from their continuous process for this new process and integrate the new batch production system with the balance of the existing plant and equipment with the least amount of rework and impact possible. The process also utilized high temperature liquid and gaseous sodium which means the piping design including pipe supports was very important for a successful project.
Solution:
Valdes performed the front-end and detail engineering for the project. Laser scanning was utilized to scan and capture the as-built condition of the existing facility and the equipment that was to be reused. This information was then turned into a 3D model to determine how the new process unit would fit into the available area honoring the client's specifications. Valdes team members from various disciplines collaborated to develop a detail design for this new plant that met the challenges presented.
Impact:
By starting with laser scanning and producing a 3D design model, significant time, money and rework was saved since the 3D model was continuously reviewed with the client for design improvements throughout the project development life cycle.
SERVICES:
Project Management
- Fast Track Project Execution
- Formal Project Communication Methods
- Strategy Development
- Financial Management
- Critical Path Schedules
- Project Risk Assessment & Risk Mitigation
- Cost Tracking & Reporting
- Cost Estimating
- Feasibility Analyses to Guide Strategic Business Decisions
- Commissioning/Start-Up Planning
Process
- Simulation & Modeling
- Studies
- Technology Evaluation & Selection
- Front-End Project Development
- Process Optimization
- PFD/P&ID Development
- Heat & Mass Balance
- Equipment Selection & Specification
- Process Equipment Evaluations
- Relief Device & System Analysis
- Utility System Design & Evaluation
- Process Control Design
- Process Scope Development
- Effluent Handling System Design
Mechanical
- Facility Design & Plant Layout
- Equipment Selection
- Material Handling & Dust Control Systems
- Rotating Equipment Sizing & Specification
- HVAC
- Fire Protection & Detection
- Plumbing
- Fluid Heat Tracing
- Blending & Mixing Systems
- Heat Exchanger Selection
- Plant Utilities
- Industrial/Hygiene Ventilation
- Equipment & Piping Specifications
- Field Walkdowns/Constructability Review
- Pressure Vessel Design
Piping & Plant Layout
- Piping Layouts
- General Arrangement Drawings
- Line Studies
- Piping Isometrics
- Equipment Arrangements
- Vessel Nozzle Orientation
- Vessel Platform & Ladder Layout
- Underground Piping Layout
- Process & Utility Piping Design
- Construction Field Support
- High Definition Laser Scanning & 3D Modeling/Design
Instrumentation & Controls
- PID Controller Application & Specification
- Instrument Selection & Specification
- Instrument Index & I/O Lists
- Control Valve Sizing & Specification
- Instrument Loop & Interconnection Diagrams
- Smart Plant Instrumentation/INtools
- HAZOP Participation
- Control Panel Design Instrument Location Plans
- Installation Details
- Instrument Commissioning
- Safety Instrumented Systems (SIS) Implementation*
- Engineering & Design in Accordance with ISA84 & IEC-61511 Standards
- HMI, MMI, & SCADA Functional Specifications
- Operator Interface Specifications
- Operator Usability Studies
- PLC & DCS
- Specification Selection
- Functional Descriptions
- Ladder Logic
- Hardware Interface
- System Architecture Drawings
- HART & Foundation Fieldbus
- Control Room Layout & Design
- Control System Training Manual
- Site/Factory Acceptance Testing
Electrical
- System Analysis (SKM Power* Tools):
- Load Flow
- Short Circuit
- Overcurrent Coordination
- Arc Flash
- Transient Stability
- Utility/Industrial & Transmission/Service Substations
- Industrial Power Distribution:
- Power Transformers
- Low/Medium Voltage Switchgear
- Motor Control Centers
- VFD Installations
- Protective Relay Settings, Generators & Distribution
- Diesel Generator and UPS Systems
- DC systems
- Grounding & Lightning Protection
- Lighting
- Equipment & Raceway Layout Drawings
- Wiring Diagrams & Schematics
- Electrical Heat Tracing
- Area Classification & Code Compliance
Civil
- Site Development/Selection
- Storm/Sanitary/Oily Water Sewers
- Stormwater Management/Permitting
- Grading/Drainage
- Containment Design
- Roadway & Pavement Design
- Underground Utilities
- Railroad Layout
Architecture
- General
- Existing Conditions Assessment
- Master Planning
- Programming
- Code Search & Analysis
- New Building Design
- Building Renovation and Addition Design
- Construction Documents
- Bridging Documents
- Bidding Support
- Construction Administration
- Sustainability (i.e., LEED, Green Globes)
- Permit Support
- Life Sciences
- Science & Technology Facility Design
- Functionality (Flow of People and Materials)
- Space (Environment & Human Impacts)
- Regulatory (FDA, GMP, HSE)
- Commissioning / Qualification Support
- Laboratory Planning and Design
- Industrial
- High Hazard Facility Code Analysis
- High Hazard Facility Design
- Design for Client Specific equipment / processes
Laser Scanning & Surveying
- Pre-Design Surveys
- Utility Mapping
- Structural Steel Surveys
- Topographic Maps
- Line & Grade Measurements
- Foundation Surveys
- As-Built Drawing Development
- Vessel & Equipment Surveys
- Spool Verification