Board Certified Diplomate Forensic Engineer
440-838-0640, 440-832-9540
www.maddenfe.com
Fixed Fee Preliminary Accident Evaluation Available
Engineering Design Activities during Employment in Engineering Design and Plant Operations which are discussed in more detail below, include:
● Design & Specification of Equipment
● Design & Specification of Systems, such as Instrumentation, Controls, Piping, etc.
● Design, Layout & Specification of Facilities
● Safety Design, as part of Equipment, Systems and Facilities Design
● Other Technical Work associated with the Engineering Design
● Equipment Operation & Testing
● Studies of Industrial Operations
● Construction Assistance
& Construction Site Engineering
● Industrial Facilities Commissioning
(final stage of construction)
● Industrial Facilities Startup
(initial phase of Operations
The engineering design categories listed above are not all-inclusive of the engineering design work performed.
Examples of Typical Systems Designed
● Utility Systems & Facilities
● Specialized Safety Facilities
● Pollution Control Facilities
Examples of Specialty Systems Designed
● Specialty Safety System Designs, e.g. gas systems overpressure relief systems
●
Designs Using Fire, e.g. elevated flares as part of gas systems overpressure relief systems
● Pollution Control Systems
●
Designs to Prevent & Fight Fire
Examples of Design Related Activities during Design Work
● Designing and Presenting Safety Design Courses
● Preparing Design Manuals, writing some sections, and supervising others in writing other sections
● Assuring Safety Design through review and approval of designs
Examples of Other Technical Activities, related to Engineering Design and Construction, while Employed in Engineering Design
● Equipment Operation & Testing
● Studies of Industrial Operations
● Construction Assistance
& Construction Site Engineering
● Industrial Facilities Commissioning
(final stage of construction)
● Industrial Facilities Startup
(initial phase of Operations
_____
Safety Design of Equipment and Facilities
● Adherence to the Safety Design Hierarchy principle
● Designing safety into the Equipment when feasible
● Using Machine Guards and Safeguards as appropriate for safety
● Including Warnings and Warnings Signage as appropriate for safety
Safety design was a routine, integral part of the engineering design of all industrial and manufacturing equipment and facilities while employed in industrial operations and engineering design.
> Safety design is based on:
- Human Factors and the analysis of the human - equipment and human - facility interfaces
- accepted engineering safety standards and practices
- Codes & Standards and Recommended Practices
> Safety design includes:
- designing equipment to reduce or eliminate hazards in the use of the equipment, which is usually called designing out the safety hazards
- the specification of safeguards (such as barrier guards, light curtains, dual operating buttons, safety instrumentation, etc.) as required
- the designing or specification of warnings as required
> Safety design is performed based on the Safety Design Hierarchy principle
● The Safety Design Hierarchy is the accepted system for the design of safe equipment, systems, products and facilities.
> The Safety Design Hierarchy requires designing for safety as follows:
- first, design out the safety hazards in equipment, products and facilities whenever possible
- second, use safeguards to protect from those safety hazards which cannot be designed out
- third, use warnings for those safety hazards which cannot be designed out and for which safeguards cannot be used to protect from the safety hazard
- fourth, use warnings to complement safeguards when safeguards are used to protect from hazards
> Design using the Safety Design Hierarchy has prohibitions as follows:
- do NOT use warnings in place of safeguards or designing out a hazard, if these are practical
- do NOT use safeguards in place of designing out a hazard, if this is practical
Other Technical Activities Associated with Engineering Design
- Conducted equipment operation testing in manufacturing facilities
- Performed industrial operation studies in manufacturing facilities, including studies to develop the data required to design additional similar facilities
- Performed drainage studies in industrial and manufacturing facilities to develop the data required for the design of surface facilities and trenches/flumes and sewers for the drainage required
- Designed specialized safety and air pollution control systems , including flares, vents, foam fire protection systems and the like
- Assisted with construction of industrial and manufacturing facilities, including providing technical assistance to Construction personnel at the construction site and providing construction site engineering design services and supervision of construction
- Designed and presented to Design Engineers covering the design of safety relief devices and safety relief systems
- Organized, participated in and supervised the writing of Design Manuals for equipment, machinery, piping, valving and instrumentation to meet safety design requirements and applicable codes, standards and recommended practices
- Organized, participated in and supervised the writing of a Design Manual for the design of boiler systems to meet safety design requirements and the ASME Boiler Code and other applicable codes and standards
- Assured the technical quality of engineering designs, especially of the safety design of equipment and facilities, design of safety facilities and warnings; through hands-on reviews and formal technical reviews and approvals of engineering designs of industrial and manufacturing facilities, piping, valving, instrumentation, equipment and machinery
- Made use of industry, technical society and government codes, standards and recommended practices extensively during design of industrial and manufacturing facilities, piping, valving, instrumentation equipment and machinery, and advised and instructed others on the proper use of these Codes in their design
Examples of Equipment and Components Designed and Specified
- Piping and tubing ranging from approximately 1/4 inch to 48 inches in diameter, used for:
- Pumps (for liquids, including water and chemicals) including:
- water
- steam
- gases
- chemicals
- pneumatic control and power systems (using air or nitrogen)
- hydraulic control and power systems (using hydraulic fluid), etc.
- Valves ranging from approximately 1/4 inch to 48 inches in size including:
- hand-operated valves
- remote-operated valves (with electrical, hydraulic or pneumatic control and power)
- automatically operated valves (with electrical, hydraulic or pneumatic control and power)
- gate valves
- globe valves
- needle valves
- butterfly valves
- ball valves
- rotary valves, etc.
- Safety and overpressure relief valves • rupture discs
- overpressure blowout panels
- Skimmers, flotation and settling clarifiers
- Non-burning vent stacks for disposal of non-hazardous gases to meet EPA anti-pollution regulations
- Gas blowers • fans
- Ejectors
- Compressors (for gases, including air and nitrogen) including:
- centrifugal compressors
- reciprocating compressors
- reciprocating positive displacement pumps
- screw positive displacement pumps
- sump pumps, etc.
- Vacuum pumps (for gases - creates and maintains a vacuum)
- Turbines, motors, and engines to drive machinery, including:
- steam-driven turbines
- gas-expansion turbines
- electric motors
- gas-fired and oil-fueled engines
machinery driven by turbines, motors, and engines includes:
- compressors
- pumps
- blowers,
- conveyors
- plastics processing equipment
- similar powered equipment
- Furnaces, including:
- safety, control, fuel, exhaust and product instrumentation systems
- piping and ductwork systems
- Direct-fired boilers • waste-heat boilers (including steam generators), including:
- safety, control, fuel, exhaust and product instrumentation systems
- piping and ductwork systems
- Heaters and heat exchangers including:
- liquid to liquid heat exchangers
- liquid to gas* heat exchangers
- gas* to gas* heat exchangers
- shell and tube heat exchangers
- double pipe heat exchangers
- multipipe heat exchangers
- plate heat exchangers
- bayonet heat exchangers
- air coolers
- tank coils
- vessel jacketing
- kettle reboilers
- thermo-siphon reboilers
- vessel and tank heaters , etc.
* gases handled by heat exchangers included air
- Dryers for solids, including:
- rotary dryers
- fluidized bed dryers
- spray dryers, etc.
- Dehumidifiers to remove liquids from gases
- Pressure and vacuum vessels and tanks for liquids and gases.
- Atmospheric storage tanks for liquids
- Storage bins for solids and particulates
- Distillation, absorption and solvent extraction columns, including:
- trayed and packed columns.
- Plastics processing equipment, including:
- compounders
- extruders
- choppers, etc.
- Conveyors, including:
- belt conveyors
- pneumatic conveyors
- screw conveyors
- bucket conveyors, etc.
- Liquid and gas filters and bag houses
- Separators, including:
- impingement separators
- cyclone separators, etc.
- Traveling cranes, traveling winches, etc.
- Materials of construction for piping, equipment, machinery, etc.
Examples of Systems Designed and Specified
These Systems were designed using Safety Design and Human Factors principles, conformed to applicable Codes & Standards, and included Safeguards and Warnings where required
- Overpressure relief systems
- including the associated piping, valves, equipment and instrumentation
- Hazardous chemical (liquid and gas) relief systems
- including the associated piping, valves, equipment and instrumentation
- Air pollution systems
- including the associated piping, valves, equipment and instrumentation
- Surface and open subsurface drainage and spill containment systems
- including the grading, surfacing, trenches and flumes
- Gravity and pressure industrial sewer systems
- Liquid and solid industrial waste disposal facilities
- including skimmers, and flotation and settling clarifiers
- Control systems including:
- automatic and manual control systems
- local and remote control systems
- pneumatic, electrical and hydraulic control systems
- including those specifically designed to assure the safety of the operation of equipment and systems
- Control system panel layouts • alarm panel layouts
- Fire suppression systems
- Steam and electricity co-generation systems (which generate steam and electricity at the same time)
- Refrigeration systems
- including machinery (compressors, etc.), controls, safety systems and piping
- Utility production systems for the production of:
- Utility distribution systems
- including piping, instrumentation and controls
- Signage, including warning signs
- Equipment and machinery layouts
- building and structure specifications
- including water, foam and inert gas systems
- steam (using boilers)
- treated water for industrial purposes
- plant and instrument air
- nitrogen, etc.
Examples of Specialized Safety Facilities Designed, including those using fire and those for fire suppression
These Facilities were designed using Safety Design and Human Factors principles, conformed to applicable Codes & Standards, and included Safeguards and Warnings where required
- Pressure relief systems for numerous industrial and manufacturing facilities.
- Gas and liquid burning flare stacks for numerous industrial and manufacturing facilities.
- Fire suppressant systems, including water, inert gas and foam systems for several facilities.
Examples of Air and Water Pollution Control Facilities and Utility Systems and Facilities Designed
These Systems and Facilities were designed using Safety Design and Human Factors principles, conformed to applicable Codes & Standards, and included Safeguards and Warnings where required
- Utility distribution systems for numerous industrial and manufacturing facilities
- including piping, instrumentation and controls
- Utility production systems for the production of:
- steam (using boilers)
- treated water for industrial purposes
- plant and instrument air
- nitrogen, etc.
for use in:
● a petrochemical, utilities and storage complex, a large group of industrial, manufacturing, utilities and storage facilities
● a lube oil manufacturing facility
● a substitute natural gas (SNG) manufacturing and storage facility.
● a pharmaceutical manufacturing facility.
● a polystyrene manufacturing facility.
Examples of Industrial and Manufacturing Facilities Designed
- Plastics manufacturing grassroots* facilities including:
- low density polyethylene manufacturing facilities
- polypropylene manufacturing facilities
- a polystyrene (styrene) manufacturing facility
- extrusion and compounding facilities (used to knead plastics) for grassroots high density polyethylene manufacturing facilities
- Petroleum processing facilities including:
- Chemical production grassroots* facilities including:
- herbicide manufacturing facilities
- ethyl hexanol manufacturing facilities
- a MTBE and paraxylene absorption manufacturing facility
- a MTBE and Dimersol manufacturing facility
- a benzene hydrofining unit
- a fire retardant manufacturing facility
- Natural gas processing grassroots* facilities including:
- Downsizing and modernization of:
- a natural gas separation facility
- a natural gasoline facility.
- Tank farms (a large number of large tanks and associated equipment, piping and instrumentation in a stand-alone facility) for:
- a facility for revaporization of liquefied natural gas
- a facility to produce substitute natural gas (SNG).
- Renovation of solvent recovery and refining facilities for a high density polyethylene manufacturing facility
- Dry ice expanded tobacco manufacturing facility.
* "grassroots" facilities, also known as "greenfield" facilities are facilities which are totally new, starting with the grading of the ground • such facilities may or may not be in a manufacturing complex with other older completed facilities
- Gas vent stacks for numerous industrial and manufacturing facilities.
- Water pollution control design for an acrylonitrile manufacturing.
- Water pollution control facility for a high density polyethylene manufacturing facility.
- a lube oil manufacturing facility
- a crude oil topping facility
- a naphtha reforming (reformulation) facility
- a gas oil separation facility with stabilization
- a natural gas processing facility and export terminal
- an underground peak shaving natural gas storage facility
- a natural gas saturates facility
- a natural gas and hydrocarbon liquids processing facility.