We started this project in the Definition phase, and despite not having the benefit of completing early phases, we made sure to conduct multiple onsite visits and walkdowns with the customer and provide onsite PE support. Our in-person attendance at 3D Model and Constructability Reviews ensured that the project was successfully completed and installed. We are proud of our team’s exceptional work and look forward to continuing to provide top-notch services to our clients.

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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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The processing and bottling facility will be located in Shelbyville, KY, near the distillery, and will be constructed with phased production expansions in mind to support future growth. The design and layout will be reflected in the process description and P&IDs, ensuring the facility’s ability to meet both current and future production demands.  

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C&I’s efforts spanned over 8 years to complete all phases. Over that time, the team adapted the project scope to address client and vendor changes, all while under close corporate observation with the high price tag.

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The criticality of this electrical gear required extensive planning to ensure the deenergizing and energizing did not result in any loss in production or safety incidents. Our team designed the equipment layout and purchased a new building to house the gear. We coordinated construction, operations, and maintenance to develop a staging plan for demolition and install.

Scope to accomplish this included larger capacity transformers, 13.8kV arc resistant switchgear with additional feeder capacity, new current limiting reactors and interconnecting cable bus. 

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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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C&I provided cost estimates at each phase gate for funding approval, procurement for instrumentation and engineered equipment, and construction packages.

The project started in mid-2015 and concluded in late 2019. Our team completed the project under budget and with very few adjustments or disruptions. With a condensed schedule and significantly long lead deliverables and delays, we worked well under the pressure to produce a quality outcome. Operations was prioritized so that the new layout was intuitive, safe, and accessible.

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We were recommended for this project by another site who was pleased with our services on a similar project at their facility. Since this facility had recently changed ownership, the client relied heavily on our team’s extensive knowledge of the new owner’s standards to assist with bringing the site into compliance. Our team successfully completed the electrical area classification drawing updates within the required timeframe, ensuring the compliance deadline was met.

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The project will design and commission equipment which allows for continuous, closed loop treatment of ASO within the HF Alky unit.  As a cost savings, existing equipment will be repurposed where safety or integrity is not compromised. Drawing upon our experience from other refineries, our process team scaled the technology to match refinery flow rates based on comparison of ASO to Caustic ratios from other existing units. Our support on this project extended beyond creating a cost estimate, we also attended our client’s presentation to management. We not only care about project design, but the entire project process and are here to help our clients in any way we can!

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Being the oldest unit in the refinery, the area was extremely congested. Therefore, C&I’s team utilized the laser scanning and 3D modeling tools to locate the new equipment and design piping. Due to real estate constraints, C&I’s team came up with a plan to place exchangers on an elevated structure to reduce impact to dike containment and avoid flooding.

Predicting 2-phase flow in the vacuum transfer line is challenging. C&I’s Senior Process Engineer, Russ Williams, presented his approach to the transfer line work in Hydrocarbon Processing article, “Simulation model of a vacuum heater transfer line,” in March, 2018.

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