Fortune 500 Chemical Manufacturer
Manufacturing Facility Design
In this project, our team helped this Fortune 500 Chemical Manufacturing client improve existing production processes, implement new equipment and systems, and increase production capacity at a key Texas facility.
This Fortune 500 chemical manufacturer is a global force with expertise across a variety of consumer and industrial markets. With thousands of passionate employees, the company promises and delivers excellent solutions to customers in over 100 countries.
When this client decided that they wanted to increase the production capacity at one their Texas facilities, they engaged Salas O’Brien to analyze the existing operations and provide engineering designs for necessary modifications to the facility. The project scope included designs for the implementation of a variety of new systems and equipment, including a Safety Instrumented System (SIS) and automated emergency purge system. One of the key challenges of this project lay in planning for upgrades to existing electrical equipment that minimized production downtime. In addition, some of the systems and equipment needed to a meet specific Safety Integrity Level (SIL) for compliance.
Our team created a model of the cooling water system that enabled us to simulate and analyze the effect an increase in cooling water flow (necessary for expansion) would have on overall system performance. During our analysis of the existing process, our team discovered a short circuit that was hampering production. We engineered a solution that would eliminate the short circuit, and we completed structural analysis and engineering designs for the necessary additions to the system. We then engineered tie-points which could be installed during the yearly plant turnaround and would allow for key process switchovers to occur with little to no production downtime. In addition, we also specified all instrumentation and controls to meet the process and SIL requirements and to integrate with the plant’s Distributed Control System (DCS) and new Safety Instrumented System (SIS). Finally, our team worked closely with the client to help adapt designs from a sister plant’s emergency purge system so that it could be properly implemented and operated.
Our work on this project empowered the client to increase production capacity, streamline existing processes, and execute upgrades with minimal downtime. The quality of our services and the integrity our team demonstrated during this project built our client’s confidence in our work and led to collaboration on many more projects.