Laser Scanning Archives - C&I Engineering

Stillage Screens and Modular Boiler Installation

Hgostling — Tue, 01 Oct 2024 14:51:20 +0000

C&I performed a front-end study and detail design for this project. The project required installation of a new water treatment and new boiler building in an operational distillery. Integration of systems must occur during a planned summer distillery outage and coincide with a major plant expansion.

The stillage from the stills is separated in new screeners and the thick stillage is pumped a considerable distance across a road and railroad track to an Anerobic Digestion facility, designed by others. After processing, the C&I team piped the RNG back to the distillery and blended it with an existing natural gas feed to power the new modular boilers. The team has navigated the challenges of working with multiple vendors, permitting entities, and engineering firms to coordinate the design and installation of this project.

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Urea Capacity Expansion

Abarmore — Fri, 28 Jan 2022 19:07:38 +0000

This client sought to increase its urea capacity from 1,300 TPD to approximately 1,650 TPD to meet increasing market demand. This is due primarily to its ability to reduce NOX emissions in diesel engines while achieving a 4% to 7% increase in gas mileage. Because of the economic opportunities realized by increasing production capacity, C&I conducted FEL-1 conceptual phase through Detailed Design, Start-up and Commissioning.

To accurately model the process changes, our team created a benchmark simulation of the entire Urea Unit. Creating a Hysys model was a challenge and had to be rigorously tested. Due to the unique chemistry of the process, the urea and ammonium carbamate components had to be created and regressed binary interaction parameters for multicomponent mixtures had to be developed. Our model was validated against a test run, providing confidence in the simulation of future operation. The process team used creativity to address the need for supplemental compressed CO₂ gas feed by using liquid CO₂ to support the overall capacity increase.

The existing unit was congested, requiring finesse in siting equipment and routing piping. This is where our expertise in retrofit design combined with the 3D modeling tool and laser scan set us up for a successful project. We were able to involve stakeholders in a constructability review early in the design process to locate several new pieces of equipment in an existing structure.

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69 kV Substation Replacement

Abarmore — Fri, 28 Jan 2022 17:23:27 +0000

The goal of this project was to replace antiquated electrical equipment, much of which was over 40 years old. Our team developed the scope from the Feasibility phase through Implementation, Start-up and Commissioning of the relay building and substation. C&I’s team drew on expertise from previous projects to assist with substation design, cutover planning and load balancing. We were able to work with the client to adjust project cash flow to coordinate with the turnaround schedule.

Due to geographical constraints, the project combined three substations into one. This resulted in multiple cutovers spread over 5 years to match turnaround outages. To make space for the new substation, several storage areas had to be relocated. After installation, the project finished $3MM under budget with minimal RFIs from construction.

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NOx Abatement

Abarmore — Wed, 29 Dec 2021 19:01:02 +0000

C&I assisted our client with specifying a SCR (selective catalyst reduction) system for removing NOx from rotary and belt calciners at a 95% or higher destruction efficiency. Defining the NOx emissions was challenging as the plant runs a variety of campaigns on each calciner resulting in several design cases used to characterize the NOx stream and establish a datasheet for the SCR unit. Several vendors and technologies were evaluated, and ultimately a system consisting of baghouse filters, natural gas burner, air fans, SCR catalyst reactor, exhaust stack, urea injection lance, mixers, and urea tank was chosen. Auxiliary equipment to the support the system included eductors for solids removal, air preheater to control header temperature, and a large collection header routed through the plant.

Utilizing our self-performed laser scan, the team was able to work with Operations, Construction and Maintenance to ensure the plant was able to use the existing NOx scrubber system while staging cut-over to the new system one calciner at a time, significantly reducing impacts to production.

C&I provided cost estimates for the FEL-3 and FEL-4 phases, procurement for instrumentation and engineered equipment, and construction packages for all upgrades.

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Hydrotreater Heater Replacement

Hgostling — Wed, 29 Dec 2021 18:03:10 +0000

C&I inherited this project from another engineering firm at the Detailed Design phase. Soon after the project began, the team was faced with challenges associated with the COVID pandemic. With limited travel, our team successfully worked remotely using a laser scan and field data gathered during the initial site visit. Our team overcame these obstacles to complete the engineering design ahead of schedule and under budget.

The scope of the project included a replacement heater with BMS (burner management system) and CEMS (continuous emissions monitoring system), new coalescing filter, and replacement of the charge/reactor effluent exchangers to debottleneck the unit and allow it to run at the hydraulic limit, increasing capacity by approximately 20%. Designing the piping to balance 2-phase flow was a critical project component. This was our first project with this client, and they were extremely happy with the execution of the project and how quickly our team learned their specifications.

“Our team was successful because we built relationships with the client team, specifically the Process and E&I representatives.”
Jason Cullens | Project Manager

This is an ongoing project. Our team is excited to see it through to installation!

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Soap Blending and Filling Expansion

Abarmore — Tue, 23 Nov 2021 14:46:57 +0000

Our team added 24,000 gallons of blending capacity for soaps and similar products within an existing facility, in addition to adding to its filling/packaging capacity. The project team had to fit new batch and surge tanks within the space constraints of the existing compounding facility, while ensuring that the needs of Operations and Maintenance were met. Additionally, our design had to be versatile enough to accommodate a variety of products and container sizes.

We worked alongside the client to develop an understanding of the technical requirements, including the information needed for raw materials and product recipes. We also worked with conveyor and equipment manufacturers to install, relocate, and modify production lines to meet the needs of the client.

Project scope included:

Four new 6,000 gallon blend tanks
Four new 6,000 gallon surge tanks
Two new pre-mix tanks (350 gallon and 500 gallon)
Two new 10,000 gallon FRP surfactant tanks
New mezzanine for two blend and two surge tanks
Modified mezzanine for two blend tanks
New sanitary valves, transfer pumps, instrumentation, and VFDs
New/relocated packaging equipment, including a bottle unscrambler, filler, cap torquer, labeler, case erector, drop packer, and case sealer
New conveyor for packaging line
Relocation of a packaging line from another facility – modified layout

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Thin Liquids Production Facility

Hgostling — Tue, 16 Nov 2021 19:23:54 +0000

This project transformed a warehouse into a new thin liquids production facility. The scope included six sets of blend/surge/pre-mix tanks, a DI/RO water system, a water tempering system, a CIP system, an automated batching/filling system, surfactant storage and distribution, and two high speed filling/packaging lines. The project started in August 2020, was commissioned in April 2021, and resulted in a blending capacity of 45,000 gallons.

Our C&I team was challenged to complete front end and detailed design engineering for this immense project in only six months. The dedication and flexibility shown by team members has strengthened our relationship with the client by delivering a blended 3D model quickly and efficiently, providing extensive coordination and communication for the client and construction contractors, and working long hours to achieve results within the timeline provided.

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Tomato Sauce Capacity Expansion

Abarmore — Tue, 16 Nov 2021 19:14:07 +0000

C&I was able to double production capacity with this plant expansion project. We provided detailed design engineering for the project as well as updating all files and P&IDs and performing a laser scan to set the basis for next steps. The laser scan allowed us to layout and modify the new equipment so that it would fit alongside existing equipment. We also set up the facility with the flexibility to switch piping to feed one line (old process) or two lines (new process) depending on their needs.

Our associates made tank modifications, installed new hot hold tank and hot kettle with metal detector, and implemented new fillers, packaging equipment, hot water set, pumps, modified product heater and hold tube. This plant is unique as it resides inside a partner’s plant, requiring interfacing and coordinating with their team as well as our client’s.

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Distillery Equipment Relocation

Abarmore — Tue, 16 Nov 2021 16:28:32 +0000

For this project, our team was able to facilitate the distillery’s expansion of their touring facilities by relocating the fermenter pump. By tucking it behind a column, we achieved optimal tour route that provided the most aesthetically pleasing result for tourist experience. Our challenge was to ensure easy access for maintenance of the pump while providing adequate space to pull the mash cooler bundle for cleaning.

In order to take advantage of a planned outage, we produced a quick retrofit design that addressed all concerns and required considerations. Our comprehensive design allowed the relocation to be conducted efficiently during the outage, avoiding delays.

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Hydraulic Improvements and Capacity Increase

Abarmore — Tue, 16 Nov 2021 16:07:53 +0000

Our team upgraded the equipment pumps and piping in the cistern room to support the barreling capacity increase. The existing piping system required reconfiguration to fix hydraulic issues with the existing pumps and integration of an additional product storage tank. To support the distillery’s addition of four barrel filling stations, we also replaced three barrel filling pumps, replaced and relocated current truck loading pump, and upsized the piping to increase flow rate through the system. And finally, we installed new plate packs in the two existing plate and frame whiskey coolers, upgraded tank instrumentation, and audited the system.

C&I was able to achieve all of this while incorporating client’s specific requests and staying flexible with changes in scope.

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