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Full Range Engineering services.

Engineering Software

Process

  • Aspen HYSYS
  • PIPENET

Civil

  • STAAD. Pro

  • Tekla Structure

Electrical

  • ETAP
  • DIALux

Mechanical

  • PV Elite
  • Compress

Piping

  • CAESAR

    (Stress Analysis)

  • ACAD

3D Modeling

  • CADWorx
  • AutoCad Plant 3D
  • AVEVA E3D
We deliver High Quality Engineering Solutions
  • FULL RANGE Architectural, Engineering, and related services.
  • Basic and Detailed engineering

  • FEED. Front End Engineering Design.

KEY ENGINEERING DELIVERABLES:

  • Full Range Engineering Design  Details.
  • Process – Design / Documents
  • Electrical – Design / Documents
  • I&C – Instrumentation & Control– Design / Documents
  • Static & Rotary Equipment– Design / Documents
  • Piping – Design / Documents
  • Civil – Design / Documents

Engineering Design Sequence and Services Details.

PROCESS – Design / Documents.

  • Simulation & Heat & Material Balance with Fluid Stream composition, pressure & temperature.
  • Hydraulics studies with limits of erosional & sonic velocity.
  • Philosophies for Isolation, Vent & Drain, Emergency Shut down (ESD), Depressurization.
  • Transient analysis of lines in different scenarios of pump startup, shut down & tripping.
  • Equipment sizing for Pressure Vessel, Storage Tanks and Thermal design of Heat exchangers.
  • Balancing Utility Consumption to define Capacities for vendor items like:

Cooling tower, Pumps, Boiler, potable water system and Instrument air compressors.

  • Flare study, dispersion analysis and PSV’s relief load & back pressure calculations.
  • Alarm & Trip Schedule and Tie ins details.
  • Cause and Effect diagram with start, stop & tripping of motors for pumps, compressor, Cooling Tower’s fans with switches & transmitter. Open/Close “Action” of solenoid valve.
  • Battery limit Identification to define work scope between Subcontractors/Vendors. And development of Conceptual schemes with battery limit conditions of vendor packages like Boilers, Turbines (Gas & Steam) and Water treatment units.
  • Process Flow Diagram, Piping & Instrumentation Drawing, Data Sheets of Equipment Valves and Special Piping Items.

ELECTRICAL – Design / Documents.

  • SLD – Single Line Diagram along with Connected load, Breaker specs, and Bus bar rating for max values of current, voltage and frequency.
  • Load list with load type as Continuous, Intermittent & Stand by, along with details of Reactive & Apparent power, Absorbed & Running load and Load factor.
  • System Studies including Load flow, Short circuit, Motor starting and Relay co-ordination.
  • Sizing, Specifications & Data sheet of:
    • MV/LV Switchgear and, MCC with component details like DOL & Soft starter, Bus coupler, Isolator, Current and Voltage Transformer and Interfacing requirement for signal exchange with plant overall control system of DCS and ESD.
    • Step up and Step down Transformer with auxiliaries details like OLTC-On Load Tap changer, Buchholz relay and air or oil Cooling requirements.
    • AC/DC UPS along with Battery bank, Full load backup requirement, Panel type and variation in input voltage & frequency.
  • Earthing & Lightening system design considering soil resistivity to design Conductor and size, number & interspacing requirement of Grounding rods.

  • Hazardous area classification for different zones in coordination with process design engineer for max value of ignition temperature and flash point.

  • Power, Lighting and Control cable Layouts in Trench, Trays, Duct bank and Cable duct, considering spacing requirements between MV, LV & Control cables.
  • Cable Schedule with specs like size, type, material, number of cores and gland size.
  • Interconnection wiring diagram with Terminal details of source and feeding point.
  • Typical Installation drawings of Power, Lighting and Grounding system for site construction team.
  • Lighting system design in accordance with min Lux level calculations and details of Lighting fixture, JBs, Lighting pole, Conduit and Termination lugs. Small Power and Lighting Distribution Board Schedule.

I &C (Instrumentation & Control) – Design / Documents

  • Instrument Index, Specs & Data sheet of Field Instruments including Gauges, Switches and Transmitters.
  • I/O List for plant overall control system along with complete detail of Tag number, Location, Loop number, Signal type and Calibration range.
  • Hook Up Drawings with connection detail between field instruments and Piping and Mech equipment along with battery limit between I&C and other engineering disciplines.
  • Cable Schedule & Layout with cable specs and cross-sectional detail inside trenches or in cable trays.
  • Grounding Layout with clean earth grounding bar system.
  • MTO/BOQ for procurement and installation of Bulk material like Stanchion for field instruments, Tubes, valve, union, connector, cap, plug…etc.
  • Interconnection diagram indicating interface between plant overall Control system with PLCs of Vendor packages and LV/MV Switchgears, Transformer and Motor Control Centers.
  • Junction Box (JB) Wiring Diagram with terminal details, shielding requirement and cable entering / leaving a particular JB to and from Field Instruments.
  • Instrument Logic Diagram and Narrative description of complex loop against each interlock defined in Cause and Effect matrix.
  • Instrument Loop Diagram required for commissioning for loop check and maintenance/trouble shooting.

STATIC & ROTARY EQUIPMENT– Design / Documents

  • Basic Design – Data Sheet and General Arrangement Drawings for:
    • Pressure Vessels (Column, Drum, Reactor).
    • Heat Exchangers (Shell & Tube, Fin Fan Cooler).
    • Water and Oil Storage Tanks (Conical, Dome & Floating Roof).
  • Detailed Calculations to decide Shell thickness, requirement of PWHT-Post weld heat treatment, MDMT Min design metal temperature, WRC analysis, Radiography, Stiffening requirement, cladding/lining requirement and MAWP (Max allowable working Pressure) by considering pressure, temperature and fluid services. Estimating data for civil foundation design like type, size and number of anchor bolts at base plate.
  • Detailed Drawings of Mechanical items including Elliptical / Hemispherical head, nozzle reinforcement and Manhole details, Lifting & Tailing lugs, Vessel supporting structure like Skirt, Saddle, Legs, Baseplate details and Platform / Ladders installed on Drums, Columns, Reactors and Storage Tanks.
  • Basic Design – Data Sheet / Specs and Vendor document review for:
    • Pumps
    • Compressor

PIPING – Design / Documents

  • Plant 3D Modelling for ease of construction and plant operation by evaluating equipment spacing and Electromechanical routing at 30%, 60% and 90% Model review.
  • Piping Material specs in accordance with Line class, Base material, Flange rating and Corrosion Allowance to define material grade and pipe schedule.
  • Critical Line list & Stress Analysis in accordance with defined criteria of max temperature, pressure, size and vibrations.
  • Piping Key Plan & Layouts indicating pipe routs, elevations along with cross
  • sectional details & arrangement at Pipe rack, Stanchion, Supports above ground or in Direct burial and inside Trenches.
  • Piping Isometrics & Trim Isometrics along with joint type of butt and fillet weld.
  • Welding categories like GTAW, SMAW and inspection level for radiography as full or spot.
  • MTO for Pipes, Fitting, Pipe supports, Special piping items and other Bulk material including but not limited to WN, LWN, Slip on Flanges, Gasket, Elbow, Tee, Reducers, Union, Blinds, Valves, Filters, Orifices and Steam Traps.
  • Piping BOQ with details like piping inch dia, area for Insulation & Sand blasting, Painting and Internal Coating, internal volume for hydro test and extent of PWHT requirement

CIVIL – Design / Documents

  • Equipment Foundation considering soil parameters like bearing capacity in accordance with Geo Tech analysis. Also considering forces and moments due to wind and seismic loads at empty, operating and test conditions of equipment.
  • Dynamic structural analysis for foundation design of heavy rotating equipment like pumps, compressor and turbine, considering vibrations, frequency and resonance.
  • Grading plan and section details along with cut / fill requirement in accordance with Topographic survey result to establish plant overall FGL-Finish Grade Level and FFL-Finished floor level for buildings.
  • Architectural & Structural design of Residential, Commercial & Industrial buildings including electrical substation and control room with special attention on foundation type as Raft, Piles or Isolated spread footing.
  • Underground services including Cable Trenches, Road Culvert, Storm Drain & Sewage Network by avoiding clash probability between different services for a hassle free design for Site construction team.
  • RCC structures like Cooling Tower, Pipe rack, Stanchion, Ponds, Pits, Dyke walls, and Blast proof and Blast resistant walls.

  • Road and Pavement with cross section and spec details for sand, crushed stone, asphalt, gravel and tough tiles at different grades

HSE – Health Safety & Environment – Design / Documents

  • Fire water network including Fire water spray demand calculations, UL/FM listed pumps, Piping network, Hydrants, Monitor, Deluge Vale & Sprinkling System.
  • Fireproofing Requirement on Vessel skirts and Steel Structure in accordance with fireproofing zones and minimum inventory of flammable product.
  • Passive Fire Protection system with Blast walls, Dyke wall around storage tanks, Vessel venting and intrinsically safe cables.
  • Vendor co-ordination for Fire Suppression system for fixed and portable foam system (aspirated & non aspirated), Fire extinguishers and Clean Agent Inergen system.
  • Safety Layouts for Escape route, Safety shower, Eye wash, Safety Sign & Hazardous area layout.
  • Third Party Safety Studies like HAZOPand SIL study based on Probability of failure on demand.
  • Estimation of potential gas leakage sources to determine Gas dispersion model for development of Gas envelope.
  • Vendor coordination for 3D mapping of Fire & Gas Detection system in accordance with Gas dispersion model as per QRA report (Quantitative Risk Assessment Report).

QA/QC Quality Assurance & Control

  • PQP-Project Quality Plan
  • QIP – Quality Inspection Plan
  • Work Instruction and SOP
  • Planning of Design activities
  • Organizational & Technical Interface
  • Design Input
  • Engineering Document Preparation
  • Design output
  • Engineering document review and verification
  • Design change
  • Progress Manhour monitoring
  • Document numbering system
  • Lesson learnt
  • Vendor document handling
  • Project document control and Transmittal system

PROCUREMENT Support Activities:

  • RFQ-Request for Quotations,
    • Vendor Clarifications,
    • TBE-Technical Bid Evaluation,
    • Vendor document review,
    • ITP-Inspection test plan for hold and witness points,
    • FAT-Factory Acceptance Test,
    • SAT-Site Acceptance Test
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