Optimization and Equipment Testing

Effective Solutions for your Capital Project

Optimization, Specification, Integration

Optimization

We can support your company in the optimization of systems design for:

  • Optimum energy consumptions vs. capital cost
  • Optimum operating flexibility and maintainability versus capital cost
  • Manage RAM (Reliability, Availability, and Maintainability) analysis with third-party partners
  • Design decisions and pre-investment for future feedstock changes or changes (usually increases) in capacity
  • Establishing efficient facility configuration and site plan
  • Economic and safe constructability

Examples are:

  • Optimized hydrogen system for a major refinery resulting in substantial scope eliminations and lower operating costs. PSA unit and hydrogen compressors were deleted from scope. A short pipeline and purchase contract for hydrogen replaced these. PSA feed was utilized as fuel. Cost-saving was approximately $20 MM.
  • Optimized maintenance isolation and blowdown volumes for light ends recovery system with centrifugal compressor, eliminating substantial scope, reducing cost, and improving maintenance safety.
  • Identified opportunity to reduce energy consumption of a cogeneration plant 100 MW electrical and 300 tonnes per hour steam production. A thermal energy saving of 14 MW was realized while reducing footprint. Capital cost was reduced by $2 MM by reducing air cooler surface and piping, and replacing this with a condensate to BFW heat exchanger. Electrical load for air cooler fans was also reduced by 38 KW.
  • Optimized plant maintainability and availability for a petrochemical facility by right-sizing boiler capacity relative to cogeneration steam generation capacity. This maintained N+1 reliability during scheduled GTG outages.

Specification, Evaluation, Design Integration

We have expertise with this equipment. Safe and economic operation, reliability and maintainability are key objectives:

  • Boilers: Drum and OTSG type
  • HRSGs: Drum and OTSG type
  • Steam-Turbine-Generator sets and turbines for mechanical drive
  • Compressors of all types
  • High horsepower pumps
  • Boiler feedwater system components including pumps and deaerators
  • Process heaters
  • Gas-Turbine generator sets and gas turbine mechanical drives
  • Speciality process units

Safe Operability and Maintainability review

Experienced in HAZOP and safe application of machinery.

Performance and Mechanical Testing

We witness performance and mechanical testing to your or supplier’s procedure

Technician working on a large industrial turbine in a factory setting.
Close-up of industrial machinery with green and red components in a factory setting.
Industrial machinery with pipes and a large engine in a factory setting.