Commonwealth provides detail design and engineering services for all disciplines.
Our services include all aspects of Process Engineering and Design from conceptual development and cost studies through detail design, procurement, construction and startup assistance. Our process engineers have experience with refining, petrochemical, chemical and power systems. Recent refining work includes both grassroots and revamps of Delayed Cokers, Hydrotreaters, Hydrocrackers and Iso-dewaxing for lube production. We have revamped FCCU gas plants, reformers, alkylation units and sulfur recovery and tail gas treating units. Utilities and Offsites experience includes flaring mitigation and flare gas recovery and tank farm design. Our chemical plant experience encompasses olefins, aromatics, polymers, and inorganic chemical unit debottlenecking and design. Other significant experience also includes power production, waste-to-energy, LNG and gas processing.
- Studies and conceptual design
- Simulations and process flow diagram development
- Heat and material balances
- P&ID/EFD/mechanical flow diagram development
- Process equipment selection, sizing and specification
- Emergency relief contingency, PSV and flare analysis and sizing
- Process hazard analysis and HAZOP studies, including safety instrumented systems (SIS) for flare load reduction
- Utilities and offsites
Services include design applications and development of equipment and material specifications, quotations and reviews and equipment/vendor selection. This follows the fabrication cycle through design reviews, fabrication drawing review and approval, vendor data review and QA/QC acceptance. As required, the mechanical equipment engineering group provides installation and startup assistance. We also have the capability of performing heat exchanger sizing and rating calculations, code design of vessels and material selection.
- Rotating equipment: compressors, pumps, blowers, motors, drivers
- Fixed equipment: heat exchangers, pressure vessels, tanks
- Fired heaters: heaters, boilers
- Specialty equipment: materials handling, flares, cooling towers, skids
Our piping design group averages nearly 30 years experience, and uses “fit for purpose” tools to meet project objectives. On revamp activities, this may involve using a mix of hand sketches and 2D/3D design, and on projects with significant grass-roots facilities we will typically use 3D. Our design platforms are AutoCAD based 2D/3D CADWorx. A hallmark of our execution is to fully understand the project design and schedule challenges, and selecting the appropriate execution approach. For example, on heavy revamp work with aggressive schedule requirements, we often recommend a design with allowances for field fitup to allow early takeoff and fabrication of spools. To assist construction and other groups, we use an area design approach to allow issuance of packages by area within a process unit.
- Plot plan development
- Layout and piping transposition (piping one-line) diagrams
- Piping material selection, standards and specifications
- Piping material control/bills of material/piping requisitions
- Stress analysis
- Laser scanning of existing facilities
- 3D Models
- Detailed piping fabrication and construction drawings
- Piping tie-in schedules
- Estimate support
- Construction/Field Engineering Support
Our civil/structural group is responsible for the site development and grading and drainage design. They perform foundation design for mechanical, piping, and electrical equipment, and design steel and concrete structures for equipment, pipeways, process buildings, and the like. They review fabrication drawings, prepare contract/construction packages to support the field effort, and provide site assistance as appropriate.
- Site development/grading and drainage
- Paving drawings
- Foundation design (spread footings and piled foundations)
- Heavy industrial steel and concrete structures (utilizing AISC and ACI Codes)
- Process buildings
- Seismic analysis (utilizing UBC, IBC, or ASCE Codes as required)
- Contract packages (narratives for contractor scope of work)
- Tankage and containment berms or dikes for product containment
Key activities include initial system load studies and distribution, and the sizing and specification of equipment (generators, transformers, switchgear, motors and drivers, cabling, etc.). Design activities involve the electrical distribution for high, medium and low voltage systems, one-line diagrams, routing of feeders, power and control cable routing drawings, cable schedules, lighting systems, wiring diagrams, grounding plans and panel design.
- Power system design
- Load studies
- Protective devices
- Short-circuit analysis
- Voltage drop calculations
- Relay coordination studies
- Arc flash hazard analysis
- Electrical area classifications
- Vendor selection and coordination
Instrumentation & Controls
Services include design, sizing, selection and specifications. We follow through to the implementation phase with controls definition, and configuration and programming capabilities. Our engineers take an active role in the technical requirements during the procurement and fabrication phase, through system checkout and factory acceptance testing. In the field, we assist the client in loop checking and systems commissioning. The I&C department has detailed experience with Honeywell, Invensys (Foxboro), Yokogawa, Emerson-DeltaV, Triconex, Allen Bradley, GE and other control systems manufacturers.
- Distributed Control Systems (DCS)
- Safety Instrumented Systems (SIS)
- Programmable Logic Controllers (PLC)
- Remote Instrument Enclosures (RIE)
- Continuous Emissions Monitoring Systems (CEMS)
- Analytical instrumentation
- Control panel design for rotating equipment and fired heaters
- Field instrumentation including control valves, relief valves, flow elements and electronic transmitters