Client-Kanpur Fertilizers & Cement Limited, Kanpur, INDIA

Project-Study of CO2 removal section piping system of Ammonia plant for vibration problem, size and thickness adequacy, flow pattern, stress analysis and isometric drawings.

The scope of work includes:
i) To check the adequacy of pipe size and pipe thickness for the piping system consisting of 10” and 12” diameter pipes.
ii) To study the flow pattern in two-phase flow pipe segments and, if there is slug flow, to suggest design modifications to avoid the slug flow if practically possible.
iii) To study the possibility of relocating the control valve to minimize the vibration problem.
iv) To study whether there is possibility of cavitation in the control valves.
v) To review design of existing pipe supports.
vi) To review existing stress analysis report.
vii) To suggest new pipe routing if there is change in pipe design to avoid vibration problems.
viii) To suggest new pipe support design if existing design is inadequate.
ix) To carry out stress analysis of the said pipe segments.
x) To develop isometric drawings with BOM (good for construction) for the said pipe segments based on above analysis.

Client-Bliss Anand Pvt Ltd, Manesar, Gurugram, INDIA

Project-Design of three-phase gas-oil-water separators

First separator handles a gas flow of 12.5 MMSCFD, oil flow of 5000 BPD and water flow of 5000 BPD operating at a pressure of 150 Bar (g). The second separator handles a gas flow of 10.0 MMSCFD, oil flow of 5000 BPD and water flow of 5000 BPD operating at a pressure of 100 Bar (g).

Client-Hyper Filteration Pvt Ltd, Sahibabad, INDIA

Project-Basic Engineering for Design of Multiple Effect Evaporation System of Thermo Vapor Recompression (TVR) type 

The Multiple Effect Evaporation System handles i) 17 m3/hr feed with initial TDS of 40000 ppm and final TDS 350000 ppm, ii) 6 m3/hr feed with initial TDS of 120000 ppm and final TDS 350000 ppm. The scope of work consists of the followings:
i) Process flow diagram (PFD) and heat & material balance (H&MB)
ii) Design and datasheet of four effect forced circulation evaporators all under vacuum, vapor-liquid separators, steam jet ejector (thermo vapor re-compressor), vacuum system (ejector plus condenser), circulation pumps, feed pre-heaters, and condensate flash vessel
iii) Design basis report (DBR) for design of evaporators
iv) Datasheet of control valves and pressure safety valves (PSV)
v) Piping & Instrumentation Diagram (P&ID)

Client-Isgec Heavy Engineering Limited, NOIDA, INDIA

Project-Front end engineering design (FEED) and conceptual design for aqueous ammonia storage system

The system consists of aq ammonia storage tank of 50 m3 capacity, sprinkler cooling and ammonia absorption system, and breather system. The system is the part of 2×20 MW power project-III of NTPC SAIL Power Company Limited at Durgapur, West Bengal.

Detailed scope of work consists of the followings:
i) Design Basis Report of Aq. Ammonia Storage System
ii) Dyke volume calculation for aqueous ammonia storage tank
iii) Calculations for Process design of breather system for zero discharge condition of ammonia vapor
iv) Process datasheet of aqueous ammonia storage tank
v) Heat & mass balance (H&MB) of the breather system
vi) Process data sheet of breather vessel
vii) Calculation report for sprinkler system
viii) Process data sheet for safety valve and vacuum relief valve on aq ammonia storage tank
ix) Process data sheet of instruments on breather vessel

Client-Agile Process Chemicals LLP, Navi Numbai, INDIA

Project-Modification of pyrolysis gas condensation system for 12 MTPD pyrolysis plant 

The scope of work includes design of three shell and tube condensers, thermic fluid system and chemical cleaning system.

Detailed scope of work includes the followings:
i) Process flow diagram (PFD) and heat & material balance (H&MB) of modified pyrolysis gas condensation system and thermic fluid system consisting of expansion tank, cooler, start-up heater, pump.
ii) Piping and Instrumentation Diagram (P&ID) for modified pyrolysis gas condensation system, thermic fluid system and chemical cleaning system for pyrolysis gas condensers
iii) Equipment datasheet of pyrolysis gas condensers, thermic fluid system (expansion tank, cooler, start-up heater, pump), chemical cleaning system
iv) Instrument datasheet of instruments for the modified system
v) Electrical load list for the modified system
vi) Utility summary for the modified system
vii) Process description and control philosophy for the modified system

Client-Agile Process Chemicals LLP, Navi Numbai, INDIA

Project-Engineering design of steam generation and pipe heat tracing system for 6 MTPD pyrolysis plant 

The scope of work includes the followings:

i) Process Flow Diagram (PFD) and Heat & Material balance (H&MB)
ii) Piping and Instrumentation Diagram (P&ID)
iii) Process Description & Control Philosophy
iv) Equipment Design & Datasheet-waste heat boiler, steam drum, de-aerator, DM water package, BFW pump
v) Instrument Datasheet
vi) Cause & Effect Matrix
vii) Alarm & Trip List
viii) Utility Summary
ix) Electrical Load List
x) Piping MTO
xi) Line List
xii) Instrument I/O List
xiii) Review of GA drawings of equipments, piping layout and piping GA drawings

Additional scope of work:
1. Flue gas stack design & drawing review and suggesting new improved design
2. Process safety review of Hot Air Generator (HAG)-review of HAG process control and instrumentation system for safe operation of HAG
3. Reactor by-pass valve (damper) design and duct sizing to control the temperature of downstream reactor

Client-Agile Process Chemicals LLP, Navi Numbai, INDIA

Project-Process optimization study for 6 MTPD pyrolysis plant for energy and cost optimization 

The scope of work includes the followings:

i) Improvement in design of hot air generator (HAG)system-combining two HAG into a single one with optimization of outlet temperature, material and excess air
ii) Replacing costly and inefficient hot gas re-circulation two ID fans with a single efficient ID fan
iii) Replacing two FD fans with a more efficient single FD fan
iv) Improved air pre-heater design
v) Optimum flue gas piping network design
vi) Knock-out drum design
vii) Heat and material balance for improved design of HAG system

Client-Pyrocrat Systems LLP, Navi Mumbai, INDIA

Project-Pre-feasibility/cost-estimation study for setting up 10000 liters/day pyrolysis oil fractionation pilot plant

The plant fractionates pyrolysis oil into value added products such as naphtha, diesel and base oil.

Detailed scope included the following:

Block Flow Diagram (BFD)
Process Description
Equipment List with broad specifications
Preliminary Equipment Layout
Capital Cost Estimation
Operating Cost Estimation

Client- Isgec Heavy Engineering Ltd, NOIDA, INDIA

Project-Engineering support including thermal design of shell-and-tube heat exchanger for Durrah Sugar Refinery project located at Yanbu, Kingdom of Saudi Arabia

The exchanger cools molasses, a by-product of sugar manufacturing process, with a viscosity as high as 17000 cP (at 40 ºC) from 50 ºC to 40 ºC with cooling water available at 37 ºC.

Client-Hindustan Petroleum Corporation Limited, Visakh Refinery, Visakhapatnam, INDIA

Project-Delivered training program on “Heat Exchanger Design” at Hindustan Petroleum Corporation Limited, Visakh Refinery, Visakhapatnam on 19th and 20th April, 2019.

Client-Centre for Industrial Solution and Advanced Training, Nagpur, INDIA

Project-Delivered training on “Pressure Safety Valve (PSV) design” on 15th and 16th December 2017 at Kolkata which was attended by engineers from Numaligarh Refinery Limited, Numaligarh and Tata Chemicals Limited, Haldia.