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Published by Plant Systems Engineering, 2017-11-29 09:29:35

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PLANT SYSTEMSENGINEERINGEngineering for the Process Industries

The Plant Systems Group, Inc 2Plant Systems Engineering507 North York St. Suite 2AMechanicsburg, Pennsylvania 17055717-795-9122 Office717-795-9525 [email protected] Web


ABOUT USPLANT SYSTEMS ENGINEERING Plant Systems Engineering was established in 1993. We have remained a small firm through the years – this has enabled us to cultivate and maintain trusting business relationships that are needed to navigate the increasingly challenging industrial arena. Our work is entirely in the industrial / manufacturing areas with specific expertise in moving bulk materials - solid, liquid or gas. We have intimate knowledge of the equipment and systems used to move and handle these products as well as the infrastructure required to support them. With 25 years of practice, we are high skilled at graphically demonstrating complex detailed designs in two or three dimensions for owner review or for construction. We value quality, integrity, the environment and quality of life for our staff and seek clients with the same core value system. This approach and keeping with our core competencies and values has enable us to prosper for twenty five 4 5

SAFETY, TRAINING Not only do our designs need to be compliant with OSHA and MSHA, our staff is trained for MSHA Part 46 and 48. Our Insurance and safety records are pre-qualified through ISNETWORLD 6

SERVICESPLANT DESIGN and ENGINEERINGBeginning with the client's concept, we develop process flows and general arrangement drawings toconceptualize the plant. Utilization of state of the art design software by SolidWorks, most designsare modeled for Pre-Construction Imaging.PSE provides all aspects of plant engineering including specifications for equipment purchasing,installation and construction and detailed structural, mechanical, piping and ducting 7

SYSTEMS DESIGN and ENGINEERINGMany times, clients wish to upgrade or reconfigure existing systemsfor greater capacity or increased environmental performance. Oursystems design work encompasses all of our markets and includes:  Bulk Material Handling and Processing Systems  Environmental Systems  Process Piping, Tank Storage and Associated Systems  Structural Systems  Process and Personnel Safety Systems  Custom Machine Design  Design-Build 8

PROCESS SAFETY and HAZARD DESIGNProcess safety, especially in industries with combustible dusts, is gaining nationalattention due to a rash of dust explosions. We are experienced in the application ofBuilding Codes and NFPA standards to meet these design challenges for manyhazardous substances:  Agricultural dusts  Plastic dusts  Coal dusts  Fugitive methane  Fuel gas systemsOur scope has included design integration of process safety systems as wellProcess Hazard Evaluation of existing facilities.Our process safety work also includes seismic bracing systems for piping, conduit,ducting and equipment in critical occupancy 9

PRE-CONSTRUCTION IMAGING 10 Utilizing state of the art SolidWorks, Pre-Construction Imaging enables you to step out of the black and white 2-D world and step into photo realistic images of your engineered project. Applications include:  Client Design Review Meetings  Contractor Pre-Bid Meetings  Presentations to Municipal and Government Agencies  Presentations to the General

FIELD SERVICES AND INSPECTIONS Field work is a big part of what we do. Many designs are retrofit into existing facilities requiring detailed structural and mechanical surveys. Other scopes include reverse engineering, as built drawings, equipment surveys and construction oversight. Inspections include:  Tank and Vessel Inspections - External and Internal  Structural and Concrete  Airflow measurements and system 11


MINERALS AND CEMENT  Crushing Plants  Screening Plants  Bulk Rail and Truck Terminals  Bulk Storage Systems  Pyro-Processing  Pollution Control Systems  Mechanical and Pneumatic 13

ENERGY AND FUELS 14  Bulk Material receiving  Bulk Storage  Dehydration and filtration systems  Skid mounted processes  ASME B31.3 Process Piping  NFPA Process

FOOD AND AG Bulk Material Receiving Bulk Storage Air Quality and Pollution Control NFPA Process 15

METAL PROCESSORS  Material Handling  Air Quality and Pollution Control  Heat Removal  Engineering and Design for Fabricators  Shop Drawings.

PLASTICS AND RUBBER Mixing and Blending Systems Bulk Unloading and Storage NFPA Process Safety Indoor Air Quality Finished Product 17

INSURANCE IAND NVESTIGATIVE  Scope of Damages and Repairs  Cause and Origin  Re-Construction project 18 19

Project Portfolio ROTARY DRYER: GRANULE PLANT Overall view of dryer building and bag house mounted above the structure.Project Requirements: A granulemanufacturer purchased a used 11’ diameterby 60’ long rotary dryer to dry crushed stone.The dryer and its drive train requiredextensive field measurements and reverseengineering to enable the design of thefoundations, material handling and pollutioncontrol systems.Solution Method:After reverse engineering the dryer shell, drive andtrunnions, our design included:• Foundations and pedestals for dryer and building.• Feed and take-away belt conveyors.• Pollution control systems considering elevated temp’s andmoisture.• Gas train and combustion air piping• Structural steel for building and supports PLANT DESIGN: MINERAL PROCESSOR Project Requirements: An upper mid- west mineral processor wanted to significantly upgrade its crushing and screening operations. Working with the client developed process flow, provide detailed engineering and specifications for the bidding and construction of this project. Project Elements:  Two crushing and screening towers  One Reclaim tunnel  Six belt conveyors  One rotary rock dryer  Three integrated dust collection systemsSolution Method:Starting with a geo-technical survey we developed foundation, structural,mechanical and electrical engineering packages for the successfulconstruction and operation of this $10M plant. The plant was designed usingSolidWorks and AutoCAD, Design review and pre-bid meetings wereconducted with the 3-D SolidWorks 20

Slip form concrete grain silos BULK STORAGE: ETHANOL PLANT Project Requirements: A catastrophic structural failure destroyed a mid-west ethanol plants bulk storage facility. Working with the owners insurance carriers, we developed a scope of damages, repairs and construction timelines for this large loss. Working with the general contractor, we help manage the re-build costs and schedules considering the compressed time line, building and environmental code issues and logistics. Project Elements:  Two slip form concrete silos  Three bolted grain silos.  One grain dryer  Closed conveyors, bridges and supports  Bucket elevators and support towers  Re-constructed electrical power and control systemsFIRE CODE REVIEW: COAL AND FUEL OIL AT CEMENT PLANT 21Project Requirements: Review process flows,general arrangements and hydrant loop drawingsof $500M cement plant upgrade pursuant to WestVirginia Title 87 (NFPA 101 Life Safety Code).Review insurance carrier requests of fire preventionPrepare submittals for West Virginia State FireMarshallProcesses Reviewed:  Above ground storage tank for No. 2 Fuel Oil.  Distribution of No. 2 Fuel Oil  Pulverized Coal kiln firing system.  Bulk storage and conveyance of coal.  Pyro-processing (clinker formation)Code Application (partial list):  NFPA 101 Life Safety Code  NFPA 30 Flam. And Comb. Liquids Code.  NFPA 85 Combustion Systems Code  NFPA 59 Utility LP-Gas Plant Code  NFPA 69 Standard on Explosion Prevention  NFPA 13 Sprinklers Pulverized Coal Silo with explosion vents, CO2 injection, CO detection, heat detection and passive mechanical isolation

DUST EXPLOSION PREVENTION: BIO-DEGRADABLE FOOD CONTAINER PLANTRoof top dust collector with explosion vents Project Requirements: A new process had been developed to manufacture bio-degradable food containers from starch based products. The starch and other minor ingredients posed dust explosion hazards requiring a complete review and application of the codes. Scope of Work:  Coordinate testing of materials at third party laboratory.  Apply test results to NFPA 61, 68 and 69 to enable design of appropriate passive and active explosion protection systems.  Review designs and calculations with the authority having jurisdiction and owners insurance.  Coordinate purchasing of all explosion protection equipment.  Provide detailed engineering design of all systems and equipment interfaces.  Oversee installationPVC BLENDING SYSTEM: VINYL WINDOW PLANT Mixing flights blend PVC virgin and regrind (screw trough cover removed)Project Requirements: A Pennsylvaniaproducer of vinyl windows wanted to accurately 22blend PVC regrind with virgin. After consideringseveral options, we determined that a screwconveyor with mixing flights would provide theright blend at the right price. The blending ratiowas established on a volumetric basis.The system was completed design-build.Project Features:  Work with equipment vendors to select  equipment. Produce all system engineering  and construction drawings.  Engineer and design structural steel for  supporting equipment  Variable frequency drives used for speed  control of screw feeders to enable volumetric  proportioning  Custom PLC controls for controlling and  monitoring vacuum loading system, hopper  levels and screw speeds CONTACT US Plant Systems Engineering 507 North York St. Suite 2A Mechanicsburg, Pennsylvania 17055 717-795-9122 Office 717-795-9525 Fax [email protected] E-mail discover more possibilities at 23

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