phone: (973) 394-9330
fax: (973) 394-9336
email: nortoninfo@nortonengr.com

Services

REFINING PROCESS

CHEMICAL PROCESSES

UNIT OPERATIONS & ENGINEERING

ENVIRONMENTAL ENGINEERING

ADVANCED CONTROL & SAFETY INSTRUMENTED SYSTEMS

TURNAROUNDS, RESTARTS, RECONFIGURATION

OFFSITES

MECHANICAL INTEGRITY CONSULTING

PROJECT MANAGEMENT

WORK METHODS, PROCEDURES, TRAINING

ALKYLATION

  • Sulfuric acid systems: planning studies, process design, troubleshooting, debottlenecking, EPC follow-up, start-up
  • HF: process design, troubleshooting and debottlenecking.  Rapid Acid Transfer System (RATS) process design and dump time calculations.
  • Safety and environmental control facilities

AMINE UNITS

  • Screening Studies for Amine unit expansions and reconfigurations
  • Process designs for grass roots and revamped Amine units
  • Troubleshooting – system optimization, amine changes, amine degradation and heat stable salt control

ATMOSPHERIC DISTILLATION

  • Screening Studies for APS expansions and crude run changes
  • Process designs for grass roots and revamped APS units
  • APS troubleshooting and start-up
  • Improved heater operation for run length extension

COKE CALCINING

  • Coke handling facilities, combustion systems, incinerators
  • Environmental Control Facilities: SOx, NOx and PM
  • System design (grass roots, expansions and revamps), start-up and, troubleshooting

DEASPHALTING

  • Deasphalter Expansion: screening study including project economics, on-sites and off-sites impact

DELAYED COKING

  • Fired heater tube failure troubleshooting, decoking operations consulting
  • Coke cutting cycle time optimization/improvement
  • Tower bottoms fouling assessment and mitigation
  • Screening Study for Delayed Coker expansion

DEWAXING

  • Dewaxer Expansion: screening study including project economics, on-sites and off-sites impacts

FLUID CATALYTIC CRACKING

  • Flue Gas scrubbing systems: technology development, process design, performance assessment, project engineering, detailed design, equipment specification and purchase, troubleshooting, operations and start-up
  • FCCU: technology improvements (cyclones, feed zones, riser terminations), cold flow modeling, process design, operating guides, troubleshooting (high catalyst losses, poor circulation), downtime studies, start-up and turnaround support
  • FCCU main fractionator: tray/packing design and rating, coke mitigation in desuperheating section. Process design, troubleshooting, start-up, operations
  • Screening Studies for FCC expansions
  • Process designs and detailed engineering follow-up for revamped FCC units
  • FCC trouble shooting and start-up
  • Electrostatic Precipitators: process design, performance assessment, troubleshooting, operations and start-up
  • Cyclones (intern & external): process design, performance assessment, troubleshooting, operations and start-up

FLUID COKING

  • Electrostatic Precipitators: process design, performance assessment, troubleshooting, operations and start-up
  • Cyclones (intern & external): process design, performance assessment, troubleshooting, operations and start-up

GASIFICATION PETROLEUM COKE / COAL

  • Planning studies, process design, existing equipment evaluations, start-up, troubleshooting
  • Gas Clean-up: particulate & sulfur removal. Planning studies, technology evaluations, process design, vendor qualification, start-up, troubleshooting

HYDROCRACKING/HYDROTREATING

  • Design Basis, process design, detailed engineering follow-up, troubleshooting, and startup support
  • Fixed Bed reactor designs (high and low pressure units), recycle gas compression systems, absorbers, amine regeneration systems
  • Cold eyes review of hydrotreating/hydrocracking systems, catalyst planning, unit performance monitoring.
  • Training of process and operations personnel

LIGHT ENDS SYSTEMS

  • Screening Studies for APS, FCC and Reformer light ends expansions
  • Process designs for grass roots and revamped for APS, FCC and Reformer light ends units  Light ends troubleshooting and startup

LUBES MANUFACTURING

  • White Oils catalyst deactivation
  • Additives manufacturing
  • Lube oil blending, batch and JIT systems design and operations
  • Lubes processing design, troubleshooting, debottlenecking, quality improvement

REFORMING

  • Design of proprietary high temperature catalytic reforming heaters
  • Revamp designs for proprietary high temperature catalytic reforming heaters
  • Process designs of grassroots Naphtha reformers
  • Screening Studies for Naphtha Reforming expansions

SULFUR PLANT

  • Tail gas clean-up unit. Process development and design
  • Process design of tail gas cleanup unit revamp

SOUR WATER STRIPPER

  • Screening Studies for SWS expansions
  • Process designs for grass roots and revamped SWS units

VAC. DISTILLATION

  • Screening Studies for VPS expansions
  • Process designs for grass roots and revamped VPS units
  • VPS trouble shooting and start-up

VISBREAKING

  • Fired heater optimization studies to optimize yield / unit run length
  • Furnace decoking operations consulting
  • Start-up
  • Fired heater coking predictive tools development
  • Process design of grassroots Visbreaker
  • Screening Studies for Visbreaker expansions

ACIDS

  • Sulfuric Acid: planning, process design, debottlenecking and troubleshooting

ALCOHOLS

  • Process design manager for large multi-unit oxo-alcohols plant in Contractor’s offices

AROMATICS

  • Design of catalytic reformer specifically to produce aromatics

  • Design, troubleshooting and debottlenecking of complete aromatics complex

OLEFINS

  • Design of pyrolysis furnaces

  • Design, troubleshooting, debottlenecking and startup of all sections in olefins plant

  • Studies on reboiler improvements for olefins towers

  • Safety studies of olefins plants

  • Process design group leader on major ethylene facility

  • Process designs of several revamp/expansion projects for existing ethylene facilities

  • Start-up leader on propylene super-fractionator utilizing heat pump compression

  • Process design of butylene super-fractionator utilizing heat pump compression

  • Operations Supervisor of propylene and butylene fractionation units

  • Process design of butane isomerization unit using IFP technology

PHENOLS

  • Nonyl-phenol (high & low chlorine) manufacturing: planning, process engineering & design, troubleshooting, startup, unit optimization

POLYMERS

  • Poly-isobutylene manufacture. Process design, start-up, troubleshooting, debottlenecking Butyl and Halo-butyl Polymers: Process design, troubleshooting, debottlenecking, start-up, new product development

  • Air emissions quantification and permitting

  • Debottlenecking studies and revamp designs for large Unipol polyethylene plant, areas included were polymerization and finishing

POLYMER DEVOLATILIZATION

  • Direct devolatilization of LLDPE, LDPE, high ethylene EP and EPDM. Conventional devolatilization extrusion equipment and LIST kneader technology

  • Air emissions quantification and permitting; emissions control technology evaluations

SPECIALTY CHEMICALS

  • Oxo alcohol manufacture. Planning, process design & engineering, troubleshooting, kinetic modeling; debottlenecking; environmental control

  • Plasticizer manufacture. Planning, process design & engineering; assessment of product grade slate change impact on plant throughput and environmental control facilities

  • Lube oil additives manufacture. (ZDDP, Ca-sulfonate, Mg-sulfonate, Polyisobutylene, Nonyl-phenol (Cl and low-Cl), Salicylic Acid, etc.) Planning, process design & engineering, troubleshooting, batch reactor optimization, batch cycle time improvement, MEI improvement; air pollution and odor control. Raw material utilization optimization and waste minimization studies

  • Air emissions quantification and permitting; emissions control technology evaluations

  • Toluene diisocyanate: process design / start-up / and operations (Supv)

  • Vitamin C: planning and process design

  • Animal anti-virus medicine: planning studies and process design

  • Tall Oil Distillation Units: planning, process design and start-up

  • Fat Splitters: planning, process design and start-up  Vegetable Oil: planning, process design and start-up

  • Soap manufacturing: revamp studies and process design including environmental efficiency improvement projects

  • Process design leader for new developmental motor oil additives unit

SYNTHESIS GASES

  • Process design manager for a partial oxidation unit to produce syngas in Contractor’s offices. Process utilized Texaco technology

COMBUSTION

  • Refinery fired heaters (furnaces) – process design, troubleshooting and start-up. Coking evaluations, debottlenecking studies, revamp and new burner process design and evaluation.
  • Fired heaters for low btu gas combustion – process design, rating, revamps
  • Low-NOx burner retrofits – Process and detailed design, installation, testing, start-up
  • Air preheat systems – process design, troubleshooting, start-up
  • Air emissions evaluations and permitting for refinery, chemical plant and utility fired heaters burning gas, oil and coal

ENERGY CONSERVATION

  • Cogeneration: gas turbine/steam turbine/fired heater/waste heat boiler. Process design, start-up, troubleshooting and operation
  • Alternative Fuels Studies – Orimulsion, coke, Low BTU Gas (LBG). Grass roots, revamps. Fuel systems, combustion equipment, heat transfer equipment and emissions control systems. Screening studies, economic evaluations, process design, start-up and troubleshooting
  • Site energy surveys to evaluate energy usage and develop prioritized list of potential energy saving projects.  Prepare process design for targeted energy savings projects.
  • High efficiency fired heater design including state-of-the art air preheater and process heat integration schemes

ENVIRONMENTAL CONTROL

  • Air emission control systems evaluations and selections
  • FCCU Wet Scrubbing Systems – process design, troubleshooting, start-up
  • Electrostatic Precipitators (ESP’s) (all processes) – process design, cost estimating, technology evaluation/assessment, bid evaluation, start-up, troubleshooting, performance evaluations, performance improvement
  • Cyclone Systems (all processes) – process design, cost estimating, technology evaluation/assessment, bid evaluation, troubleshooting, performance evaluation, performance improvement, start-up
  • Flue Gas Desulfurization (Wet, Dry, Throw Away, Regenerative)– process design, cost estimating, technology evaluation/assessment, bid evaluation
  • Selective Catalytic Reduction (SCR) Systems – process design, cost estimating, technical evaluation/assessment, bid evaluation, start-up, troubleshooting, performance evaluation and improvement
  • Selective Non-Catalytic Reduction (SNCR) Systems – process design, cost estimating, technical evaluation/assessment, bid evaluation, start-up, troubleshooting, performance evaluation and improvement
  • Fabric Filters [reverse air and pulse jet] troubleshooting, technology evaluation/assessment, commercial project development and project engineering
  • Carbon adsorption system applications and evaluations
  • Cryogenic (refrigeration) system evaluations
  • Absorption system evaluations
  • Condensation systems evaluations

FLUID MECHANICS

  • Solid – Liquid slurry system design, troubleshooting
  • Liquid – Gas system design and troubleshooting
  • Liquid, Gas and Slurry distribution systems
  • Piping network analysis

FLUID SOLIDS

  • Shale retort systems. Process design, technology development  Spent shale cooling system development, design and patent
  • FCCU performance/troubleshooting/ cold flow modeling: standpipe pressure buildup, regenerator entrainment, dilute phase conveying, regenerator air distribution, catalyst/vapor separation, stripping
  • FCCU design: main vessels, risers, standpipes, feed zones and injectors, cyclones, air spargers/grids, slide valves, stack valves, tertiary cyclone systems
  • Particulate morphology

FRACTIONATION

  • FCCU main fractionator: tray/packing design and rating, coke mitigation in desuperheating section. Process design, internals detailing, troubleshooting, start-up, operations
  • Simulation, design, debottlenecking and troubleshooting of ethylene plant primary fractionators, refinery and chemical plant light ends towers and amine and aqueous towers
  • Super-fractionator designs for polymer grade propylene and separation of isobutylene from butane-2

HEAT TRANSFER

  • Solids heating and cooling. Fluid bed conveyors, pneumatic conveyor systems. Patents on several devices for solids heating and cooling. Process design, operation, troubleshooting, debottlenecking, start-up
  • Simulation, design, debottlenecking and troubleshooting of heat exchanger networks and individual heat exchanger services
  • Design and operation studies for enhanced surface exchangers, plate exchangers, spiral exchangers, and high flux tubes

REACTION SYSTEMS

  • Extrusion based system for manufacture of organo-silane functionalized polymers. Process development, pilot scale testing, planning studies, process design
  • Design of CSTR and fixed bed reactors

RHEOLOGY

  • Developed laboratory test methodologies for assessing the behavior of dry (devolatilized) polymers, wet polymers and polymer solutions, at plant processing conditions
  • Extrusion processing specialist: reactive extrusion, dewatering, drying, direct devolatilization, dissolving (solventizing), melting

SEPARATIONS

  • Developed proprietary models for evaluating liquid – gas separation capabilities of structured packing CaCl2 Drier upgrade/expansion for C4 Unit: process engineering & design

WASTE WATER TREATMENT

  • Assessment of existing facilities: to handle increased loadings; to meet more stringent discharge requirements; alternative / modified operating conditions; debottlenecking; operating cost reduction; troubleshooting Process definition/design of new grass roots treatment facilities
  • Heavy metals removal and recovery
  • Evaluation of emerging technologies

WATER TREATMENT

  • Water softening: process design, planning
  • Clarification: process design, planning, troubleshooting.
  • RO systems: planning, process design and troubleshooting

NOX CONTROL

  • Technology Evaluation and Selection for Petroleum Refining, Petrochemical, Utility and Industrial Applications
  • Technology and Process Development of Drop-in Control Options
  • Retrofit Control Applications: Combustion Modifications, Ad-on Systems, Additives, etc.
  • Troubleshooting and System Optimization – Performance, Chemistry, Operating Cost Reduction
  • Fluid Catalytic Crackers, Heaters (Furnaces), Boilers, Gas Turbines, Other Combustion Sources
  • Process Design, Detailed Design Follow-up, Start-up and Operations Support

SOX CONTROL

  • Technology Evaluation and Selection for Petroleum Refining, Petrochemical, Utility and Industrial Applications
  • Technology and Process Development of Drop-in Control Options
    • Wet and Dry Flue Gas Scrubbing
    • Additives
    • Regenerable and Throw-away Systems
  • Troubleshooting and System Optimization – Performance, Slurry Chemistry, Operating Cost Reduction
  • Grass Roots and Retrofit Control Applications
  • Process Design, Detailed Design Follow-up, Start-up and Operations Support

PARTICULATE EMISSIONS CONTROL

  • Technology Evaluation and Selection for Petroleum Refining, Petrochemical, Utility and Industrial Applications
  • Technology and Process Development of Drop-in Control Options
    • Wet and Dry Electrostatic Precipitators
    • Wet Scrubbers o Bag Houses
    • Cyclones (Primary, Secondary and Tertiary Cyclone Systems)
  • Troubleshooting and System Optimization – Performance, Additives, Operating Cost Reduction  Grass Roots and Retrofit Control Applications
  • Process Design, Detailed Design Follow-up, Start-up and Operations Support

WASTE WATER

  • Technology Evaluation and Selection for Petroleum Refining, Petrochemical, Utility and Industrial Applications
  • Technology and Processes
    • BOIX, DAF, Sedimentation, Centrifugation
    • Wet Gas Scrubber Purge Treatment Systems
    • Heavy Metals Removal
    • Storm Water Systems
  • Stream Compatibility Assessments
  • Troubleshooting and System Optimization – Performance, Additives, Operating Cost Reduction
  • Grass Roots and Retrofit Control Applications
  • Process Design, Detailed Design Follow-up, Start-up and Operations Support

EMISSIONS QUANTIFICATION

  • Chemical Manufacturing; Petroleum Refining; Combustion, Utilities, General Manufacturing, Mobile Sources, Transportation

PERMITTING

  • Air Quality (Title V; New Source Review, PSD, Compliance Assessments), Wastewater, Solid Waste, Hazardous Waste

CONTROL TECHNOLOGY EVALUATIONS

  • Evaluations: BACT, RACT, MACT, LAER Reviews; System Design, Selection, Process Integration, Optimization, Prepare/Review
  • Bid Spec Packages. Odor Control

COMPLIANCE TESTING

  • Protocol Development, Stack and Fugitive Emissions Testing, Testing Oversight
  • Test Data Evaluations and Certifications
  • Alternative Monitoring Plan Development
  • CEMs System Design and Troubleshooting

REGULATORY NEGOTIATIONS

  • Permit Conditions
  • Enforcement Actions Support
  • Expert Witness Testimony

RISK ASSESSMENT

  • Air Emissions Impact Modeling

ACCIDENTAL RELEASE

  • PSM, RMP, Integrated Contingency Plan: Hazard Assessments, Hazard Analysis, Plan Preparation, Modeling

ADVANCED PROCESS CONTROL (DMCPLUS)

  • Basic Control Loop Performance Evaluation and Improvement
  • Dynamic Model Development
  • Steady State Model Optimization
  • Controller Commissioning and Tuning
  • Controller Performance Monitoring/Revamp
  • Operations and Economics & Planning Personnel Training
    • Controller Operation
    • Unit Optimization
    • Operating Target Clarification
  • Inferential Product Quality Modeling
  • Online Equipment Troubleshooting Systems

BASIC AND SUPERVISORY CONTROL

  • DCS Entity Configuration
  • Control Scheme Design/Implementation
  • Operator Interface Development

SAFETY INSTRUMENTED SYSTEMS

  • Automatic Shutdown Systems
  • High Integrity Pressure Protection Systems
  • Burner Management Systems
  • DCS Based Safety Interlock Systems & Components
  • Safe Operating Limit Evaluation
  • HMI Layout/Ergonomics

TURNAROUND PLANNING – PROCESS

  • Identification of Limits: Hydraulic, Heat Transfer, Distillation

  • Unit and Equipment Capability Assessments

  • Design for: Replacement, Expansion, Performance Improvement, Operations Improvement

TURNAROUND PLANNING – MECHANICAL CONDITION ASSESSMENT

  • Mechanical Integrity Assessments

    • Rationalization of historical work list, RBI recommendations and Operations Needs

    • Identification and prioritization of critical needs

    • Development of Condition Assessment Plan

    • Effective utilization of turnaround inspection resources

    • Maximum use of noninvasive global screening methodologies to reduce turnaround time and costs (Maximize Preturnaround Work, Minimize Discovery during Turnaround)

  • Application of Proprietary Unit Specific Acceptance Criteria to Streamline Turnaround Decision Making Process

  • Proprietary Repair Technologies to Address Anticipated Deficiencies Allowing Clients to more Effectively Plan their Turnaround

TURNAROUND SUPPORT – MECHANICAL

  • Onsite Technical Expertise: Metallurgical, Mechanical, Fitness for Service, NDE Inspection

  • Rapid Response Metallurgical Evaluation

  • Development and Assessment of Repair and Reconditioning Methods (QA/QC)

  • All Refining, Petrochemical, Utility, and Environmental Processes and Equipment

TURNAROUND SUPPORT – PROCESS

  • Identification of Critical Repair/Reconditioning Needs

  • Development and Assessment of Repair and Reconditioning Designs

  • Focus turnaround efforts on what needs to get done  All Refining, Petrochemical, Utility, and Environmental Processes and Equipment

BLENDING

  • Just-in-time multi component blending facilities: wax, lubricants and fuel oil. Process design, operations, troubleshooting

BOILERS

  • Rebuild of water walled industrial boilers including new combustion systems, controls, water treatment, etc. Process design, detailed design, equipment evaluation, project management, preparation of operating guidelines, development of remote monitoring control systems, performance testing, start-up

  • Fabricator evaluation & selection, expediting, compliance with project specifications (TQA)

  • Rebuild of 1920’s firebox style industrial boiler, including retubing and updating combustion systems including controls

CAUSTIC UTILIZATION

  • Refinery spent caustic reduction/reuse assessments. Identification of opportunities for cascaded reuse of partially spent caustic; reduced caustic consumption by modifying operating conditions

  • Evaluation of technologies for treating sulfidic spent caustics. Wet Air Oxidation; bio-treatment; 3rd Party Recycle Use of alternative alkali/neutralization agents

COMPRESSION SYSTEMS

  • Sour gas recovery

  • Refrigeration: ammonia, propylene, ethylene. Process Design, troubleshooting, debottlenecking, start-up.

  • Troubleshooting and solutions of axial flow fan erosion problems

CONDENSATE SYSTEMS

  • Steam: debottlenecking / revamp of steam condensate systems in refining and chemical manufacturing facilities to accommodate plant expansions / contractions / additions and changes in onsite facilities

  • Emissions quantification of steam condensate from process heating applications.

COOLING WATER SYSTEMS

  • Revamp of 200,000 gpm system including new cooling towers – New Jersey

FLARE SYSTEMS

  • DRE evaluations, emissions quantification

  • Contingency analysis and pressure balance studies on existing and to be modified plant flare systems

FUEL GAS SYSTEMS

  • Refinery fuel gas systems – collection, distribution, drying, treating, automated analysis, control systems. Process design, debottlenecking, troubleshooting

  • Low Btu gas systems – collection distribution, drying, automated analysis, control systems and industrial boiler and fired heater revamps. Process design, troubleshooting

STEAM SYSTEMS

  • Revamp of 600# industrial steam system including extraction turbines, process and building heating. Process design, detailed design, project engineering and management, and operations

  • Steam generator design: FCCU regenerator WHBs; fired heater steam generation coils, industrial water and fire tube boilers. Process design, troubleshooting, debottlenecking

PRODUCT & RAW MATERIAL STORAGE

  • LPG storage facilities – process design

  • Hydrocarbon storage facilities – onsite and offsite tankage, transfer facilities (including marine facilities), metering, fugitive emissions control, oil loss, tank gauging systems. Process design, project development, project management & engineering, operations, troubleshooting

  • Hazardous waste storage facilities: planning, process design, project engineering, start-up, regulatory reporting.

  • P2S5: bulk solids handling systems including metering and environmental control facilities: planning, process design, project engineering, start-up

PACKAGING & SHIPPING

  • Bulk polymer pelletizing, drying and packaging facilities, polyethylene, EP, EPDM, Butyl rubber

  • Lubricating oil bottling facilities: oil blending, raw material receiving (bottles, boxes, etc.), high speed filling lines, labeling, packaging, palletizing and warehousing. Process design, operations, troubleshooting, debottlenecking, project management & engineering

  • Polyethylene pelletization, storage, packaging and shipping facilities: planning, process design, EPC follow-up, startup, troubleshooting and debottlenecking

  • Polypropylene pelletization, storage, packaging and shipping facilities: planning, process design, EPC follow-up, start-up, troubleshooting and debottlenecking

  • High temperature liquid polymer packaging: planning, process design, EPC follow-up, start-up, troubleshooting and debottlenecking

HOT OIL SYSTEMS

  • Part of Low-sulfur MOGAS facilities – Benicia CA

  • Part of Lubricant Additive Plant – Marseilles, France

  • Part of Devolatilization facilities for polymer plants – various locations

  • Screening and design of hot oil system for the Oxo Alcohols unit at Baton Rouge Refinery

  • Operation supervisor for downstream fired heater vapor generation unit for plant reboiling and heating services

REFRIGERATION SYSTEMS

  • Ammonia, Propylene, Ethylene. Process design, troubleshooting, debottlenecking, start-up. Various locations

POWER GENERATION

  • Grassroots plants, added capacity, revamps. Cogeneration, combined cycle, simple cycle, CHP. Technical and Financial Screening Studies. Project Management, construction, performance evaluation, testing, start-up. Planning studies. O&M cost planning and optimization

​

DUE DILIGENCE

  • Refinery Evaluations for major units and other chemical manufacturing and utilities components

EQUIPMENT ASSESSMENT

  • From new construction, re-rating, reconfiguration, condition assessment and fire damage restoration of Hydrotreater Reactors, Towers, drums, rotating equipment, piping, pipelines and terminal facilities

TURNAROUND PLANNING AND EXECUTION

  • Experience with turnarounds on planned and unplanned basis for all types of refining, petrochemical and utility plants from 9 months to days. Coordinated mobilization, assessment, repair strategy development, implementation and return to service of various equipment such as vessels, heat exchangers, piping and other components

CORROSION/MATERIALS ENGINEERING

  • Provided latest in diagnosis and latest application of corrective actions in a wide spectrum of damage mechanisms and corrective actions

REGULATORY AND SPECIFICATION COMPLIANCE

  • Working knowledge of applicable API RP’s and standards in addition to various corporate specifications (TEP’s, REP’s, EGG’s and others)

RISK BASED INSPECTION

  • Subject matter expert for all refining, utility and most petrochemical systems and components in a variety of leading RBI Methodologies

FAILURE ANALYSIS

  • Local laboratory capability for rapid analytical turnaround and providing terse and insightful replacement/repair direction in a timely fashion

PROPOSAL REVIEW

  • Commercial and technical evaluations

  • Contractor recommendations

  • Proposal preparation

  • Source testing protocol document preparation

PROJECT SCHEDULING

  • Project planning, engineering design, procurement, equipment fabrication and delivery

  • Start-up scheduling

  • Project size: 0.5 – 50 M$

  • Tools: Primavera, Microsoft Project

PERMITTING

  • Environmental permitting to support both operations and project execution

  • FCCU operating permits and environmental control facilities permitting

  • FCU operating and construction permits

  • Negotiations with regulatory authorities for environmental permit approval

CONTRACT MANAGEMENT

  • Engineering, Procurement, Construction, Start-up phases

  • Cost Control and Contract Change Management

CONSTRUCTION SUPERVISION

  • Technical Advisor

  • Performance Testing, Start-up

FABRICATION

  • Supplier evaluations and selection

  • Contract Negotiations

  • Fabrication cycle management

  • Deliveries sequencing and logistics

  • Process Specific Quality Assurance/Control

  • OWNER’S ENGINEER

  • FEL design leader in Contractor’s offices

  • Post FEL project follow-up. Process and equipment specific

  • Detailed design follow-up

  • HAZOP reviews

  • “Cold Eyes” reviews

PROJECT REVIEWS/FACILITATION

  • GAP Analysis

  • Value Engineering (Cost Reduction)

PROJECT ENGINEER

  • FCCU scrubber from planning (FEL-1) through detailed design

  • Pulse Jet and Reverse Air Fabric Filters – planning (FEL-1) through start-up

  • ESP – planning (FEL-1) through start-up

COLD EYES REVIEWS

  • FCCU technology package (ExxonMobil); FCCU revamp designs, yield estimates, operations test plans

  • Hydrotreating, Hydrocracking, EPR, Alkylation, FCCU emissions control, Coke Calciner, Visbreaking, Reactive Extrusion Processes, Atm & Vac Distillation Debottlenecks, etc.

  • Project cold eyes reviews from screening to start-up

  • New technologies for heavy oil recovery

  • Technical readiness assessments for new technologies (SATCON, NOx control, Alkylation, FCC SCT, etc.) HAZOPS

  • Reactive extrusion systems, pilot plant and commercial (Castrol, Dow Corning, ExxonMobil)  Wet Gas Scrubbing system (ExxonMobil)

  • Hydrotreaters, Hydrocrackers and FCC units

  • Flue Gas Desulfurization Systems (ExxonMobil, Syncrude)

  • Toluene diisocyanate (TDI) manufacturing

  • Ethylene, aromatics and polymer plants

  • HAZOP leader on many refining and chemicals projects

VALUE ENGINEERING

  • Wet Gas Scrubbing System (ExxonMobil)

  • Lubricant Additive Plant (Infineum France, SA)

  • Fired Heaters and Boilers

  • Selective Catalytic Reduction systems for NOx control

  • Proprietary Solution Polymerization Plants

  • Automatic Lube Oil Blending Facilities

  • Bulk Hazardous Materials Storage Facilities

  • Hydrocracker

  • Various chemical processes

  • Butyl plant expansion, new polymer processes evaluations

ENERGY CONSERVATION

  • Fired heaters: performance assessment, debottlenecking, revamping, T/A assistance, troubleshooting, operations and reliability improvement

  • Boilers: performance assessment, debottlenecking, revamping, T/A assistance, troubleshooting, operations and reliability improvement

  • Heat exchanger network evaluations and optimization

  • Unit heat integration optimization

  • Refinery wide steam system optimization

  • Inter-unit heat integration optimization

  • High efficiency heat exchanger systems

  • Vacuum system energy optimization

  • Heat exchanger fouling assessment, cleaning and fouling mitigation

  • Steam turbine/electric motor alternative selection

  • Waste water treatment unit energy minimization

  • Cooling water system optimization

  • Refrigeration system optimization and refrigerant change evaluations

DESIGN GUIDELINES

  • Developed standardized design methodologies for: fired heaters and boilers; FCCU Scrubbers facilities; FCCU scrubber water treating facilities; ESP facilities; and FCCU Cyclones

  • Authored Process Design Manuals for central engineering groups including: heat transfer equipment, vapor/liquid separation equipment and systems, fluid mechanics, environmental control facilities, plant utility systems, fluid solids facilities (FCCU & FCU), solids handling systems (coke and chemicals), devolitalizing and drying extrusion equipment, piping design, safety instrumented systems, etc.

PROPRIETARY TECHNOLOGY DEVELOPMENT

  • Reactive extrusion process for organo-silane polymers

  • FCCU scrubber and purge treatment technology

  • Hydro-visbreaking process

  • FCCU deNOx technology

  • Shale oil recovery processes

  • DOE sponsored Advanced Fired Heater Development

  • Scanfiner, dealkylation, pressure swing reforming and Flexcor T

  • Ethylene, aromatic and polymer plants

  • Ethylene Propylene Rubber (EP, EPDM) Commercialization (Sinopec) OPERATING GUIDES  FCCU, Wet Gas Scrubbers

  • Hydrotreaters, Hydrocrackers, Atmospheric and Vacuum Distillation, light ends systems, Amine and Sour Water Units, Alkylation units, Dimersol units, CCR units, Steam Reformers, PSA units for hydrogen recovery

  • Electrostatic Precipitators

  • Third stage separators and FCCU flue gas expanders

  • Various chemical plants and units

  • Heat pump compression fractionation units

  • Heaters and boilers

TECHNOLOGY ASSESSMENT PROCEDURES

  • Technology evaluation / assessment protocols for integration with project FEL / staged gate cycles

  • Systems / procedures for technical and process development and commercial readiness assessments PRODUCT DEVELOPMENT

  • Application and or process specific product development for cost reduction, process improvement, or energy savings by integration of engineering technologies. Wet Gas Scrubbers, Fluid Solids Equipment, Pneumatic Conveying Equipment, Heat Transfer Equipment

  • Environmental issues/control assessment from concept to commercialization for specialty chemicals START-UP SUPPORT

  • Visbreaker

  • Delayed Coker

  • Polymer devolatilization & finishing facilities

  • Fuel oil blending facilities

  • FCCU ExxonMobil affiliates and licensees

  • Hot oil systems

  • Startup leader for grass roots FCC units

  • Hydrotreater, hydrocracker and light ends units

  • FCCU Wet Gas Scrubbers ExxonMobil affiliates and licensees

  • Electrostatic Precipitators ExxonMobil affiliates and licensees

  • Cyclone Systems ExxonMobil affiliates and licensees

  • Ethylene, aromatics and polymer plants

  • Toluene Diisocyanate plants

  • Olefin super-fractionation units

  • Tall Oil fatty acid distillation units

TRAINING

  • Operators/Operations

    • Processes

    • Equipment Specific Operations

  • Technologies o Refining Processes & Integration

    • Chemical Processes

    • Separations Technologies

    • Environmental Control Technologies

    • Combustion Systems

    • Advances Controls