Port Wentworth, Georgia

Mixed Bed Polisher (MBP)

ENERGY OPTIMIZATION PROJECT NO. PW13901

BY AUSTON BAGNAS (MBP DESIGNER)

YEAR 2016

Project Overview:

This project is intended to remove impurities from the boiler feed water process.

This facility would be located before the boiler and reduce contaminates from entering the boiler system.

Contaminates can clog or foul piping within the boiler system.

This would affect the quality and quantity of the process and may require additional shut down maintenance periods to repair any damage caused by these impurities.

Ideation Process:Layout:

The vendor supplies assemblies were skid based equipment and had no layout requirements. Layout was primarily dictated on available space and distance between assemblies.

Placement:

An existing building scheduled for demolition was chosen to house the facility.

Process:

Since this facility polishes boiler feed water it was located at the near the boiler feed water tank.

Maintenance:

The mill had a lot to say about the general arrangement on this project. Maintenance and operations from the mill helped determine how this facility would operate. Therefore the layout was greatly determined by the accessibility to the assemblies in the facility.

(Picture: different skid locations & questions)

Piping & Instrumentation Diagram (P.&I.D.s)A flow diagram, or piping schematic, is used to show the process flow for a facility or process.

This design was a collaboration with the vendor, myself, and the project engineer for the CRP facility.

This flow diagram best represents how the piping will be designed. It also locates instrumentation and assemblies that will be installed.

This drawing is a valuable source of information for other drawings such as the piping plans, isometrics, tie-in drawings, and can further be used by operations after installation.

General Arrangements (G.A.s)The general arrangements are drawn to show tank & vessel locations along with the structural design and sometimes maintenance access. These drawings are very basic for clarity.

Piping Plans & Sections

These drawings show the piping layout, vessel locations, and structural information. The P.&I.D.s, G.A.s, Tie-in drawings, and isometrics will be the primary source for information when installing prefabricated items on this project.

MBP 3D ModelA 3D model was created to best identify any layout concerns.

The skids & vessels were created and inserted along with the chemical containment and any large bore piping.

Multiple disciplines were incorporated into the design. Access for electrical and instruments were considered. The structural department located steel members based on a stress analysis of the building. Foundations were designed to accommodate pumps and vessels. A containment was designed and added as well.

Many existing vessels and structures were used in this project. They were also modeled to show any interferences and possible uses.

MBP 3D Model (cont.)Alternating views were utilized for orientation and installation of assemblies and equipment. Instrumentation was able to identify locations for instruments and junction boxes based on space and accessibility. Repair, removal, and maintenance was also considered in locating any equipment.

Sample locations were installed for operations to conduct necessary analysis of the process.

This model was also used by construction to better understand how the facility would look when installed.

Construction & Installation

After pipe and vessel fabrication construction crews began installation of the facility. Here are two photos taken during the construction phase of the MBP facility. Scaffolding is erected for access and installation of piping.Minor field modifications were made. I was onsite and able to work through some unforeseen challenges.

Installed, commissioned, & running.December 2016 the MBP was finally brought online and is now successfully polishing condensate and removing impurities from the boiler feed water.

There were a couple lessons learned on this project, one including an over designed feed pipe but nothing substantial.

Overall the project was a great success and finalized on time and on budget.