Performing Risk Assessments: Dust and Process Safety

Publications

Background of Safety Risk Assessments In 1992, OSHA launched Process Safety Management (PSM) to address industries that handle highly hazardous chemicals, under OSHA Standard 29CFR 1910.119. This standard seems straightforward but was revolutionary in its impact on process safety improvements across multiple industries where flammable, combustible and toxic chemicals are used in sufficient quantities to pose a hazard to personnel or public safety. One of the fourteen elements of PSM that has been an indispensable tool in managing chemical hazards is the Process Hazard Analysis (PHA). A PHA is a systematic way to identify the hazards and quantify the risks…

One of the Biggest Mistakes I See During Construction

Thirty years as a consultant engineer has taught me that typical projects are broken into four major phases: feasibility, preliminary engineering, detailed design, construction and start-up. While the engineering phase is the most critical for your project’s development, the construction phase is the most complex. It’s when the rubber hits the road, when most of your budget is being spent, and when things could go wrong with even the best relationships sometimes ending in dispute and litigation. During the construction phase, there is a lot of complexity dealing with multiple contractors, subcontractors, vendors, equipment suppliers, government oversight, safety,…

Chemical Company Debottlenecking

ADF Engineering assisted a chemical company in increasing production by 10% initially and an additional 20% by addressing inefficiencies and optimizing various systems.

Secondary Containment Evaluation

A chemical company working with Lysine wanted to develop an overall facility site map drawing to show secondary containment volumes for each process area.

Iowa Ethanol Plant Expansion

The Iowa Ethanol Producer needed to repurpose existing buildings and structures, as well as add two new buildings, to be able to install a new DDG decanting, drying, and loading system. This project started in the conceptual phase and went through…

Relief Device Sizing For Highly Hazardous Chemical Applications

Various clients have a need to document and verify sizing of relief devices for processes that use chemicals regulated under OSHA 1910.119, the Process Safety Management of Highly Hazardous Chemical (PSM) regulations. These devices are sized and the system evaluated…

High Performance Lubricant Plant Design

The client approached ADF Engineering with a preliminary engineering design for a high performance lubricant plant which was to be an extension of their existing oil and lubricant facility. This project involved specification of a significant amount of process equipment…

Cooling Water Capacity Study For Major Ethanol Plant

The client, a major U.S. ethanol producer, was experiencing seasonal shortages of cooling water capacity, resulting in high fermenter temperatures and poor yields. ADF Engineering was asked to evaluate their cooling water balance and to provide a best value options…

Biodiesel Plant P&ID Development And Conceptual 3-D Modeling

The client needed preliminary engineering for development for a 45 MGY Biodiesel crush plant. The project included: Development and compilation of Intelligent P&ID’s Preliminary equipment sizing Development and compilation of equipment specifications Obtain and compile preliminary vendor Quotations Conceptual 3-D…

Wet Corn Mill Conversion to Ethanol Production

The client needed detailed process engineering, equipment layouts, and piping design and drawings for the conversion of a Wet Corn Mill to a 30 MGY ethanol production facility. The project included: Mass and Energy balance for the facility both wet…