Study and Review of the Basic Engineering Design (BED).
Development of piping and Instrumentation Diagrams (P&IDs).
Utility mass and heat balance & it's respective P&IDs.
Specification of effluents.
Single phase pressure drop calculation.
Two phase pressure drop calculation
Pressure drop calculation in process network
Equipment Sizing and Process Data Sheet (PDS) of the following:
Two phase separator (Horizontal/ Vertical)
Three phase separator (Horizontal with weir/ Horizantal with boot/ Vertical)
Flare K.O.Drum(Horizontal/ Vertical)
Thermal Rating of shell & tube heat exchangers
Pumps and Compressors etc.
Process Calculation for safety System
Estimation of PSV loads for various contingencies
Relief Valve Sizing Calculations as per API 520, 526
Estimation of PSV intel outlet line sizing
Flare header network sizing
Flare stack calculations
PV, RV, EV calculations for atmospheric storages
Material Design basic as per Process parameters
Flare Header Sizing
Line List, Static & Rotating Equipment List and Instrument List
Datasheet for packaged items
Fire Water System (Storage Tanks, Pumps, Headers, Sprinklers)
DM Water System Design
Cooling Water System Design
Hazard and Operability Study
Basic Engineering Design Package (BEDP) containing all data needed by a competent contractor to perform the Detail Engineering.
Mechanical - Static Equipment’s:
Manjughosh Engineering Service has a strong team of engineers experienced in Detailing & design engineering of Mechanical Equipment. Some of them have a unique blend of experience working in manufacturing & consulting companies.
Static Equipment Detailing
Key strength of Manjughosh Engineering Service is Static Equipment’s Design. Director of the company himself has 20 years of experience in design of Package units & Static equipment. More than 700 Static Equipment’s have been designed.
Manjughosh Engineering Service has extensive strength of key people for Static Equipment Design.
For technical information on Static Equipment
In Mechanical Engineering the word “Static Equipment” is given to any equipment which is in Static mode of motion or does not have rotating part. Application of Static Equipment is broadly used in Process Industry which cover, Refinery, Chemical & Fertilizer Plant.
The purpose of Static Equipment is to hold the fluid generally at a pressure in an enclosed container, for storage or for any reaction/process to take place in the container. Large volume of liquid at atmospheric pressure is store in “Tank”. This includes, Design Calculation and Detailed Fabrication drawing with BOM.
Static equipment are classified in different ways.
I- Based on Container shape
Spherical Vessel, also known as Horton Sphere
II- Based on Application
a. Pressure Vessel - for storage or for some process operation
b. Heat Exchanger – for transfer of heat
c. Distillation Column – for heat and mass transfer
d. Reactor –
In Static Equipment design we cover following different type.
Pig launcher & receivers
Air Cooled Heat Exchanger
Air Cooled Steam Condenser
We are executing:
Pressure Vessel Design using PV-elite/Compress: Calculation of
Pressure part (shell and head thickness, nozzle thickness,
Forge flange design), non-pressure part, design (saddle, skirt,
Stools, shipping saddle, pipe davit, lifting lugs, rigging analysis)
of Pressure Vessels, Tall Columns, Reactors, Heat Exchangers, Scrubber, Steam Drums, Separators Cold & Hot, Silencer, Filters, Sulphur traps, Air cooler, Storage bullet, API Tanks, Ejectors, Pig Launcher etc.
Mechanical - Rotating Equipment’s:
Manjughosh Engineering Service undertake complete design and engineering of Rotating equipment. Our activities include:
Selection, Sizing, Data sheet preparation, Vendor document review, Material, Requisition Preparation, Technical Bid evaluation.
In Rotating Equipment design, we cover following different type:
· Loading Arms
· Lifting Crane & Hoist.
· General Industrial Pump
· API 610 Pump & Seal Plan
· ANSI PUMP
· Air Compressor
· O2, N2, H2, CO2 Compressor
(Mechanical) Package Equipment's:
Manjughosh Engineering Service doing complete engineering of following packaged equipment’s:
Elevated Flare Package
(HRSG) Heat Recovery Steam Generation Package
Chemical injection Package
(GDU) Gas Dehydration Package.
(GSU) Gas Sweetening Package.
(R&R) Reactor Regeneration Package.
Reactor agitator Package.
CCR Platforming Package.
(WHRU) Waste Heat Recovery unit.
Boiler Package (Steam / Smoke tube).
LP & HP heater
Cooling Tower System.
API Fired Heater (Mechanical)
Manjughosh Engineering having vast experience of API Fired heater designing and detailing. Company provides services for Basic Design & Detail Engineering for heat transfer equipment’s, lump-sum turnkey supply of fired heaters, waste heat boilers, De-Nox systems and high-pressure and special type shell and tube heat exchanger. I includes below mentioned activities:
· Mechanical Data Sheet Preparation, which include mechanical design calculation.
· Material Requisitions Preparation
· Technical Bid evaluation
· Vender Document Review
· Detailed Engineering drawing.
· Mechanical design and detailing of API Fired Heater.
· Mechanical design and detailing of Steam reformer.
· Refractory Furnace: sizing of equipment, refractory.
· Refractory anchor design.
· Instrument connection nozzles.
· Mechanical design and detailing of APH
· Hot and cold flue gas ducting.
· ID / FD fan
· Burner hot and cold air ducting.
· Damper design with linkage system.
· Heater doors and port
· Heater steel stack.
· Platforms and ladders / stairs.
· Heat exposed pressure part radiant / Convection section
· Non-pressure part support bracket of Ni-Cr material,
· Convection shoot blower and stem lancing
· Non-pressure part support bracket with end header box.
· Ceramic fiber / Refractory LHV wall construction
· Insulating brick construction.
· 87.17 MW Duty SRT VI Hydro wax cracking Heater for shell Eastern Petroleum Ltd.
· 50.28 MW Duty SRT III Gas cracking Heater for Shell Eastern Petroleum Ltd.
· 52.98 Gcal/h Duty SRT VI Naphtha cracking Heater for Ethylene Unit Salavat.
· 41.50 MM Kcal/h Duty Process+3.33MM Kcal/h steam, Vacuum twin cell cabin Heater for Formosa Petrochemical Corp.
· 121.86 MW Duty steam reformer, vertical tube Heater with APH for KINEF Kirishi Russia.
· 13.1 MW Duty Reactor Feed oil furnace, Horizontal tube cabin Heater for Fortum oil &Gas OY.
· 4.54 MW Duty Recycle, Vertical Cylindrical Heater for Fortum oil & Gas OY.
· 53.05 MW Duty Crude and Vacuum, twin cell Vertical tube box Heater, with overhead Convection and stack with APH System.
Our Piping Engineering team undertakes following activities for complete plant engineering:
Piping General Arrangement Drawing (Plan & Elevation
Line list and Value List
Pipe Stress Analysis
Piping Support Index/Schedule
Pipe Support Drawing
Plant Modeling in 3D
Vendor Document Review
Our team has capability of working on various type of design software's including PDS, PDMS, CadWorx, AutoPlant 3D, AutoCAD, NavisWorks Freedom and CAESAR
Civil & Structure
INSTRUMENTATION Manjughosh Engineering Service performs many Process Engineering functions including: Technical bid summary preparation. Selection of instrument based on the service. Review of P&ID. Preparation of Instrument Index, I/O list in SPI or other tools. Calculation of size/ range /calibration range of instrument (Valve, Safety valve, all type of flow meter, Level gauge, thermowels, transmitter etc,). Preparation of design basis for the instrumentation and control system. Preparation of control strategy for the whole plant. Block diagram of the control system. Specification for Systems like DCS, SCADA, ESD/SIS, HIPPS, F&G and any other special system. Hazop, LOPA. SIL study. Preparation of Specification for pressure, temperature, level and flow instruments. Preparation of data sheet for control valve, On/Off valve, Motor operated valve, safety valve, measuring orifice, restriction of orifice, Magnetic flow meter, mass flow meter, Vortex flow meter, turbine flow meter, all electronic transmitter, pressure and temperature gauge, Sensing element, Load cell, JB, Instrument cable etc., Technical bid evaluation of the above instrument and Systems. Vendor document review for all instruments and systems. Specification for package vendor instruments, Package vendors document review. Grouping of instruments, preparation Junction box schedule, cable schedule for home run cables, Modeling of instruments, supports, Junction Boxes, field panels/LCP /Remote I/O cabinets, cable tray, Trench, Duct bank/ road crossing using SP3D, PDMS and other tools. Participate in inter discipline/ clients- model review, to make the model clash free. Review of piping isometric drawings for all instrument critical lines. Extraction/ preparation of instruments layout drawing. Preparation of instrument hook up, based on service condition (liquid, gas, cryogenic, two phase or special condition). Assignment of Hookup/ installation drawing in SPI, Preparation of MTO. Performing inspection of instruments at vendor’s factory. Attend FAT at system vendor’s factory. Attend meeting with client, resolve the observation if any. Calibration of instruments at site, Perform SAT, installation of all field instruments and systems, Loop checking, commissioning of systems. Resolutions of clients’ queries / punch point for success full operation of the plant.
1) Steel Structure Fabrication Drawings:
Making 2D fabrication drawing of Truss, Purlin, sag rod, beam, bracing, crane girder, gantry girder, wind girder for all kind of tall structure, technical structure, pipe rack structure, supper structure, ware house, Industrial factory structure, cement plant structure, stores and domestic and commercial buildings structure, Gates, TV
Tower, Cellular phone towers, Sky folding & sine board structure etc.
2) 3D TEKLA Model:
3D TEKLA modelling for all kind of steel structure to generate fabrication drawing with BOM.
1) Technical Support overseas client.
Apart from the Core & Strong Design and Detail Engineering Support, We are having an ethically trusted group of professionals who are engaged in promoting multinational companies in Indian Market.
In last one decade or so, Indian Markets has emerged as one of the most growing market in the world. At present many organizations / companies look forward to enter this market but do not know the local market conditions, local rules and procedure.
Thus, our company helps such organization / companies who already exists in India or want to expand their horizon and market in India for different sectors like oil and gas, petrochemical, fertilizer, Power, Steel, energy solutions and infrastructure etc.
As we are providing continuous engineering support service for foreign companies who are either having or upcoming projects in India, we obliged:
1- Core Administrative Support:
Arrangements visa, Hotels, Logistics / Local transport, providing office space with all facility within office and any other administrative support within the capacity.
2- Technical & Project Management Support:-
· We are committed and supporting the Project right from the proposal stage to till the end of project execution / handover to end user.
· Support and Participations in Pre-Bid, Post-Bid, Technical Clarifications / Queries Meetings, Kick-off Meetings, Project Review Meetings, Technical Review meetings with client etc.
· Preparations of Project Schedules using various software’s i.e. Primavera, MS office, MS Project etc.
· Actively be the part of routine correspondence between various stockholders throughout the Project Life Cycle for smooth communications and project execution.
· Participate in Site Visits, and Site Meetings.