Assisted client in developing a skid mounted pilot plant. Developed process flow diagrams, process and instrumentation diagrams, as well as all equipment and instrument specifications. Much of the equipment and instruments were subject to extremely low flows and high temperature (2000º F). R&D was responsible for developing overall architecture for controls and power distribution as well as detailed PLC and SIL rated shutdown system for reactor heating. This project also included the detailed design of the off-sites including utilities, control room, raw material handling and storage and product handling.

This project involved the installation of a new 13.8 KV distribution switchgear (dual source with tie breaker) and a double-ended 480 V distribution system. Project included a new concrete block electrical equipment building along with power transformers, cable tray distribution system, structural supports and 1100 feet of new 13.8 KV substation dual main feeders and cable tray system.

R&D was hired to provide the specification and design for a new cooling tower and associated equipment that was required due to the future increase in plant production and required additional cooling capacity. R&D provided the detailed design for the concrete cooling tower basin, pipe rack supports, piping, pumps, filters, electrical power and instrumentation.

R&D was requested to analyze several locations for the purpose of installing a one million gallon storage tank complete with volume containment. The tank was designed to be supported on a concrete mat foundation with the containment being provided by concrete walls. Specifications were provided for all the supporting equipment including exchangers, pumps, filters, electrical power, and instrumentation.

Created an impedance one-line diagram of the facility within a power analysis software program. The facility electrical equipment including feeders, transformers, switchgears, motor control centers, and protective devices were modeled based upon existing plant documentation. The short circuit analysis was performed in accordance with applicable ANSI and IEEE standards. This study included verification of existing equipment ratings to identify any misapplied equipment. A protective device coordination analysis was performed to determine the correct settings for the protective devices. Coordination curves were developed to verify and document settings.

Plant wide Arc-Flash Analysis was performed in accordance with NFPA 70E and IEEE 1584 to estimate the Arc-Flash incident energy available at all points in the distribution system. Arc-Flash labels were produced which defined the approach boundaries, flash protection boundaries and the class of personal protection equipment required.

This project involved the installation of an alloy tubed water jacketed reactor in an existing operating structure. The existing structure required extensive STAAD analysis and structural reinforcing in order to support the additional loading from the reactor. All supporting pumps, filters, exchangers, piping, electrical and instrumentation controls were specified and designed.

This was an environmentally driven project to eliminate underground piping for contaminated waste in multiple process units throughout the plant site. The underground piping was either removed or abandoned in place and replaced with open trenches covered with grating. The existing concrete sump and pumps were replaced with a double containment stainless steel sump complete with a leak detection system and new pumps with level control. R&D personnel were responsible for all detailed design, hydraulics and specifications.

The object of this project was to eliminate production bottlenecks throughout the process in order to increase production capacity. The project was multi-faceted and involved the replacement of several pieces of equipment including pumps, reactor agitators, tanks, piping, electrical switchgear, and instrument controls.

The purpose of this project was to install additional piping and instrumentation to allow one train of a reactor section to remain on-line while the catalyst in the other train was being regenerated. An increase in the production was achieved upon the successful completion of construction. This project consisted of pre-turnaround work and an ambitious shutdown schedule.

R&D personnel were responsible for providing the detailed design packages to install the project in the two phases. The detailed design required extensive piping stress analysis (due to the alloy steels and high temperatures involved), together with all electrical, instrumentation, and demolition work.

R&D’s responsibilities included site selection and resolving environmental issues to the satisfaction of the plant environmental department. The project consisted of the detailed design and specifications required to install two (2) rubber lined storage tanks, an HCL railcar loading rack, piping to and from the storage tanks, two (2) loading pumps, new pipe racks, a vent scrubber together with all electrical and instrumentation.

This project involved converting existing natural gas fueled generators to run on acetylene off gas. R&D personnel were responsible for coordinating with Cogen Supplier to ensure smooth transition. Project included all structural, piping, electrical, and instrumentation required to convert three Cogen units.

R&D provided front end process design and detailed engineering for the installation of a new product in the existing unit. The scope of the project included new storage tanks, reactor, pumps, product weighing scales, bag unloader and revamping the product vacuum system.

Included were scope books, expansion of their DCS system along with civil, mechanical, and instrument/electrical detailed design.

The detailed design included all foundations, structure, piping, electrical power and instrumentation required to complete the installation.

R&D’s scope was to provide design and construction drawings that were issued in two (2) individual construction packages. Each package involved a multi-discipline effort including piping, civil/structural, and instrumentation, electrical and mechanical. The majority of the work involved the installation of three (3) product storage tanks, new reactor pumps, exchangers, filters a truck loading facility, concrete structure for elevated reactor, and load cells for filling.

This project involved the installation of a new Insecticide Unit in an abandoned steel structure. This project took advantage of using existing storage tanks and vessels for raw materials and product. This project installed three (3) new agitated process vessels equipped with half-pipe heating and cooling jackets along with one (1) new main reactor equipped with disperser and agitator, as well as half-pipe heating and cooling jacket. Project involved structure rework, solids handling, drum heating and dispensing, transfer pumps, heat exchangers, filters, tank farm storage, rail and truck loading. Process was completely batch controlled by a new Yokogawa DCS system.

This project consisted of upgrading two (2) existing centrifugal compressors, changing process from Freon refrigerant to KLEA 123a refrigerant, installing larger 2,250 HP motor and larger gear box, and redesigning foundation to alleviate vibration and downtime. Compressor ran at 6,400 RPM with an outlet pressure of 180 psig.

This project involved the following: Identification of all vessels and pipelines containing material which would endanger the plant, plant personnel or the public in the event of a spill. We identified all structural framing in buildings and pipe racks which supported the hazardous equipment. Drawings were prepared locating and registering all such structural framing members. All identified structural framing members were inspected and reports were written indicating their condition and any required repairs. Upon the completion of the inspection phase a system of periodic re-inspections was established to insure that all critical structures are properly maintained. Upon completion of this project, R & D Consulting was designated as the Responsible Engineer for the Structural Integrity of their plant.

This project consisted of the design of a major three tier pipe rack running from one end of the plant to the other, together with pump upgrades to the process water facility and the design of new process water header, steam line and nitric acid line. The project included all electrical and instrumentation required to install the project.

This project consisted of the installation of a new reactor, agitators, transfer and cooling pumps and a bulk bag unloader. The project involved the modification and strengthening of the existing structure. The process was completely automated and interfaced with Johnson/Yokogawa DCS.

R&D’s scope was to provide design and construction drawings that were issued in two (2) individual construction packages. Each package involved a multi-discipline effort including piping, civil/structural, and instrumentation, electrical and mechanical. The majority of the work involved the installation of three (3) product storage tanks, new reactor pumps, exchangers, filters a truck loading facility, concrete structure for elevated reactor, and load cells for filling.

R&D's responsibilities included equipment arrangement, underground leak detection system, design and installation documents for major equipment including towers, screens, pumps, exchangers, reactors and railcar loading facilities.

R&D’s responsibilities included equipment arrangement design, equipment specifications for major equipment including tri-deck vibrating screens, crushers, duct work, dust collection system, railroad loading facilities, conveyors and all supporting structures. Electrical and instrumentation included design, specifications and purchase requisitions for all equipment including PLC interlock control systems.

This project consisted of the design of a six (6) level structure, design and specification for a vertically mounted air condenser, glass lined columns, heat exchangers, pumps, filters and stress analysis for the complete piping system. The electrical and instrumentation effort included the design and specifications for all equipment and PLC control systems.