STANDARD OPERATING PROCEDURES

Preparation of start-up and general Standard Operating Procedures (SOP’s) for specific plant operations. These procedures are required to inform Plant personnel of the general purpose of the procedures, the levels of responsibility, and a step-by-step checklist of what specific tasks must be performed in an orderly manner. The procedures also will include warnings of High Hazards. Some of the many procedures that were generally developed for the company’s specific issues included: general training of plant personnel, general safety, confined space entry, and lockout / tag-out of electrical, hydraulic, pneumatic, water, gas, propane, steam, and other power systems, various permits, fire response, as well as general start-up and restricted entry procedures and hazardous material spill response. In addition, numerous specific SOP's have been developed which are tailored to specific plant machinery and equipment; these include waste water treatment systems, cooling tunnel, finish oven, cranes, overhead carriages, storage tanks, pumping systems, R/O systems, motors, conveyors, general filtration, hot water supply system, motor control centers, power distribution centers, PLC Systems, HMI Systems, variable frequency drives, networks, emergency generators, and general HVAC equipment. These procedures are held by the plant manager and are available on-site for plant personnel, sub-contractors, etc. to provide for general safety, start-up, maintenance and troubleshooting procedures.

PONCE INLET FLORIDA MUNICIPAL BUILDINGS
Electrical and systems design for City Hall, Police Station and renovated Fire Hall. Emergency systems, lightning protection, power, fire alarm, HVAC power, outside and roadway lighting, telephone, radio and other systems. Completed for M.P. Spychala & Associates (Consulting Engineering).

Fuel Additives Plant – Qatar, Persian Gulf (27 substations)
Electrical Power three circuits 3@ 33kv, plus 6600v, 400v 50Hz as well as lighting, socket outlets, earthing, emergency generators (8), lightning protection, telephone, intercom, fire alarm & fire & gas system, cathodic protection system, access control system, CCTV system, substation electrical monitoring power system (SCADA), and UPS (40kVA each); DC 48v power supply systems. All specifications and FEED (front end engineering design) for a 1.5 X 1.2k M plant to be constructed in the Persian Gulf and expected to be $700mm in construction value. Completed for Mustang Tampa (Engineering Consultants)

HELICOPTER STABILIZER PRESS MODIFICATIONS
This project involved a stabilizer molding press imported from France. The main project required the machine to be upgraded electrically to meet the current E.S.A requirements (O.H.E.S.C), with the addition of grounding, properly sized fuses and wiring and a short circuit study. Troubleshooting of electrical, pneumatic and hydraulic circuits were performed. As-built drawings were created on CAD for the various electric, pneumatic and hydraulic systems. French to English Translations were provided for existing drawings and the maintenance manual. Also included was tagging of all field devices such as limit switches, hydraulic and pneumatic values.

MULTIPLEXED FIRE ALARM SYSTEMS
· Multiplexed Fire Alarm System for very large plant of farm manufacturer. This system consists of (8) eight peer to peer fire alarm control panels, linked with fibre optics for communication, individual panel operation, voice communications, radio communications, numerous pull stations, smoke detectors, pressure switches, valve tamper switches, smoke detectors, heat detectors, alarm bells, alarm horns, strobes, etc. annunciator panel, computerized monitoring equipment, and specialized interfacing equipment to shutdown various plant equipment.
· Preliminary review and creation of report on study of various Building Automation Systems for tractor manufacturing plant.
· Design of major fire alarm system expansion for farm equipment manufacturing plant.
· Modifications and expansion for existing Fire Alarm System for manufacturer.

NATURAL GAS MANUFACTURING PLANTS
· Yearly Fire Alarm Systems Test at Natural Gas Processing Plant.
· Modifications to existing Natural Gas Processing Plant/Co-generation Plant. This includes PLC programming, PLC I/O additions (Allen Bradley SLC-5/03), 75 HP Soft Start, modifications to existing MCC for several new motors, modifications to existing lighting panels, junction box schedules, cable and conduit schedules, hazardous area ratings, wiring diagrams, P&ID drawings, instrumentation loop drawings, creation of manuals, addition of plant processing equipment, startup and debugging, training, etc.
· Total replacement of existing PLC system for a new PLC System (Allen Bradley SLC 5/05) for a natural gas manufacturing plant. This was a turnkey project as well, involving PLC programming, electrical design, startup and debugging, creating of drawings, manuals, training, etc.
· Modifications to Natural Gas Processing Plant for additions of two new brine pump systems.
· Creation of electrical Asbuilt Drawings and P&ID Drawings for a Natural Gas Processing Plant.
· Electrical 24 VDC Power system for converted Gas Drilling Rig. Work included electrical design, startup and debugging, testing, battery load calculations, grounding design, fog horn, navigation lights, DC/DC Converters, autodialer, cell phone, VHF Radio, 60 Amp, 24 VDC Generator, low voltage sensing system, breaker panel, power panel, antenna's, electrical drawings, manuals and various troubleshooting assistance.
· Continued programming revisions to Allen Bradley PLC5/30B Processor and Panelview 1200 Graphics Screen, for various plant modifications to a natural gas manufacturing plant.
· Revisions to existing PLC program, for creating a totally unmanned natural gas compressor station. This required electrical control modifications to the plants emergency power generation, emergency shutdown system, boiler control systems, pump controls, as well as the implementation of new additions of instrumentation, UPS systems, and power monitoring relays. Programming such as auto-dialer programming, and PLC programming where required to tie in all new equipment and further automate the plant to become unmanned. Creation of asbuilt drawings, and updating of site manuals.
· Revisions to existing PLC programs, for various natural gas compressor stations, emergency shutdown systems, auto-dialer programming, addition of a Sulfur Analyzer, with tie-in to PLC, various modifications, etc.
· Performed Y2K Tests on PLC Equipment and Graphic Screen Equipment, as well as related software issues. Created reports and recommendations for the client.

SOLVENT TANK FARM MONITORING SYSTEM
·Wonderware InTouch Ver 7.0 addition of logging system, for data collection such as operator log on and log off, pump run times, pump start/stop times, product selected, tank filled, valves opened/closed and quantity filled. PLC Programming of Allen Bradley SLC 5/05 Processor for Paint Manufacturing Solvent Tank Farm (20 tanks).
· Create MMI (machine man interface) graphic screens using Wonderware Intouch version7.0.
· Complete design of electrical control system, communications system (Ethernet - 10 Base T), bar code system and tank level monitoring system, etc. For Paint Manufacturing Tank Farm (20 tanks).
· Electrical Systems Study and Asbuilts for Paint manufacturing Plant.
· Proposed design of PLC surge protection systems study at paint manufacturing plant.
· Perform Year 2000 compliance tests (Y2K) on Allen-Bradley Programmable Logic Controllers (PLC's).
· Create fully documented PLC programs and graphic screen programs.

NEW SUBSTATION
Change in the existing 4800 volt system to a 34.5 KV system increasing the available capacity to 17,000 KVA from the current 4500 KVA, first by the use of overhead busway and then by use of underground cables to individually mounted 4500 KVA pad mount transformers with fans. This plant consists of approximately 98% motors for refrigeration process as well as having a high degree of process mechanical loads for packaging and freezers.

SHORT CIRCUIT AND CO-ORDINATION STUDY
Provided a short circuit and fault current study and review of the existing 5,000 KVA and 2500 KVA pad mount distributions systems (parallel) for doubling plant expansion. Field review of approximately 900 motors and 11 Motor Control Centres in the 250,000 sq. plant. Purpose to increase the amount of refrigeration substantially up to 25,000 KVA for addition of new freezers. Provided 5 year plan for expansion, review of existing distribution system including hot spot locations and general code violation changes required to comply with the U.S. National Electrical Code.

PROCESS AND INSTRUMENTATION DRAWING
Provided a review and instrumentation, asbuilts of existing plant, refrigeration system for compliance with environmental standards, requirements for the State of New Jersey including P&ID’s, safety valve calculations distribution, control and PLC ladder diagrams. As an offshoot of this project the corporate engineers has asked us to provide standards for all their instrumentation and piping for issue to the various vendors for their 30 plants throughout the world (ongoing).

AUTOMATED CORIAN SANDING LINE
Provided the preliminary and detailed design for finishing of corian product. Engineering work included mechanical piping, pump selection, platforms, tank design, 5 micron filter selection, air piping and utilities, electrical motor contact sub-station, primary feeders, instrumentation, P&ID’s, equipment selection, PLC programming and compatible supervision and master line control of 13 pieces of equipment and automated line. Started up equipment and provided field debugging of electrical and automated instrumentation systems.

NEW PRODUCTION FACILITY
Design of new production facility for the manufacture of proprietary plastic coating materials.
Phase 1: Structural and architectural work and underground services for construction of the building.
Phase 2: Mechanical and electrical work , included two pre-purchased custom air handling units and other systems for heating and ventilating of hazardous rated and non-rated areas.
Phase 3: Coordinated with Phase II installation of three process ovens.
Phase 4: Installation of oven exhaust solvent removal systems, exhaust fan, incinerator and exhaust stack. Process piping, fire protection, plumbing, pumps, unit heaters and other equipment were selected and installed. Electrical work included a new substation, area lighting, HVAC controls, smoke and fire alarm systems.

POWER PLANT & RECTIFIERS MODIFICATIONS
This project involved an increase to plant capacity of 3500 KVA to serve increased rectifier load. Provided design specifications and installation details for replacing galvanizing line rectifiers and installing new outdoor transformers, new secondary switchgear and new rectifier distribution wiring. Performed capacitor switching and filter study due to harmonic disturbances from non-linear loads (rectifiers).

PRIME OVEN REBUILD
This project involved the field personnel assignments for refurbishing and redesigning the instrumentation and control system for the revisions to the refabricated oven subsequent to an explosion that demolished a significant portion of the oven. Personnel provided field inspection, new design and calibration as well as start-up assistance to the new project. The staff was commended for their excellent work on the project.

PREVENTIVE MAINTENANCE PROGRAMS
This project involved the increase in preventative maintenance procedures for the plant. Work included generation of forms interface with P&ID's for equipment and instrumentation references and data and a completion schedule on database and scheduling. Work involves the use of data ties and extensive use of time-line AutoCAD and Primavera scheduling programs. Programs will also be interfaced with the Data General Main Frame MIS system.

PAINT LINE AS-BUILT DRAWINGS
This enormous project is broken down into several large projects, including detailed as~builts, and production of new and existing drawings of a 48 million dollar Paint Line. The project involved producing electrical drawings, instrumentation drawings, panel layout drawings, hydraulic drawings and gas valve train drawings, all stored permanently on AutoCAD.
Various detailed drawings we produce for all sections of the Paint Line such as the Prime Oven; Finish Oven; Metal Prep; Heat Recovery; Supplementary Heat; and Prime/Finish Coater Heads, for near future automation projects and maintenance files.

RESERVOIRS CONSTRUCTION
Construction of two – 400,000 gallon reservoirs, 4,000 and 8,000 gallon duplex primary lift stations, filtering and monitoring. This project involved civil (roads, tanks, sewers). Structural (foundations and steelwork), mechanical (overhead piping, carbon filters, primary filters and extensive valving), and architectural (building modifications as well as a new building). A new electrical sub-station, primary and secondary feeders, motor control, instrumentation, P&ID’s equipment purchase and panel designing programming were also part of this project.

PHENOLIC RESIN PROCESS EXPANSIONS
New process equipment installations increased the phenolic resin production capacity of this plant. The projects progressed on an extremely aggressive schedule to meet the requirements of a corporate acquisition agreement. Both liquid resin and powdered resin production facilities were part of this expansion.

CONSTRUCTION ESTIMATES
This project involved working hand in hand with Plant Engineers to provide appropriation grade construction estimates as part of an overall plant modernization program to update their plant 13.8 IV distribution system to increase system reliability. The client provided general scopes of work on what they wanted to achieve in increasing system reliability. Members of the staff then conducted detailed field surveys and provided site plans, one-line diagrams and equipment layouts with construction estimates on proposed methods to accomplish the task. The various schemes were reviewed with the Plant Engineers at various stages of the project to coordinate the efforts of all parties. As an example, one project involved the modernization of one of the main 13.8 KV indoor switching substation; the work consisted of replacement of existing obsolete 25 Hz switchgear and 60 Hz switchgear with a new line up of 15 KV 60 Hz switchgear. To improve system reliability, the proposed new switchgear line-up would have a dual feed arrangement with a bus tie switch. A new cable tray system was proposed to eliminate conduit congestion. As part of this project a new HVAC system was installed to provide an environmentally controlled room due to the harsh outside corrosive environment.

KETTLES BATCH CONTROLLER ADDITION
This project consisted of developing and designing a batch controller system capable of producing ten different recipes. The system contained various instrumentation components such as a mass flow meter, four pen circular chart recorders, flow transducers, current to pressure transmitters and a G.E. Series I plus programmable controller. Setup, start-up, debugging and commissioning were all included a part of this project.

LABORATORY RENOVATION
Design and construction documents for the renovation of a 10,000 SF laboratory facility. Work involved the design for new heating, ventilating and air-conditioning systems for the entire building, new exhaust systems for laboratory areas, and the addition of a room pressure control system to maintain negative pressures within lab areas in relation to adjacent offices.

FREE TRADE COMPLEX - INCUBATOR FACILITY
Develop a quality design solution for an incubator facility directed at Canadian Companies located in the Buffalo/Western New York Area, as a result of the Free Trade Agreement.
The execution of this task was accomplished through a program of design objectives; overall site planning with a parallel development of multiple building types.
Building project was completed and their field (shop )drawings for HVAC and energy Management systems including debugging, start-up and programming of the systems.

ELECTRICAL AND INSTRUMENTATION CONTROL SYSTEM
Provided engineering support for a new facility designed for high sulfur coal research. This facility is part of State Electric and Gas Company’s 600 MU Power Generating Station. Detail engineering design was provided for electrical, instrumentation and mechanical disciplines on a design/build basis. Sixteen subsystems on main high sulfur coal loop were involved. Electrical construction of 4mm including sixteen different PLC programs and interface to overall computer system.

NEW COMMUNICATION SYSTEM
Telephone, Life Safety and Electronic Surveillance systems: Services included the drawings and specifications for the installation of building fire alarm, sprinkler supervisory, and building security system complete with remote dial-up and double backup capabilities. In addition, the system included an alphanumeric printer and RS232C interface to the Town computer, and remote monitoring of pumping stations.

COMMUNICATION SYSTEMS
The changes in the existing telephone system for the whole of Niagara county involved 13 different buildings with 7 switches being changed from CQ Centrex to EPBX systems internally with 7 new switches. The installation of fibre between all facilities, traffic control data, paging, answering, fax, rerouting of calls from one end of the network to other to save money, ARS (automatic route selection) and all features for monitoring the performance of the 7 switches. During the financial analysis on the system installation against fees paid prior to the telephone company, the net savings (over 5 years) was 4 million dollars.

POWER DISTRIBUTION AND SUBSTATIONS
Relocated and redistributed loads to five distribution substations during plant rearrangement, including revisions to electric furnace switching systems, revisions to Magnablast power breakers to add vacuum bottle switching. Completed a Cooling Water study to provide a cooling tower system to replace an evaporative pond. Work included complete investigation, analysis and specification of tower and pumping system.

POWER DISTRIBUTION
As part of an overall plant modernization the 12 KV grounded distribution system was also modified. This portion of the electrical work consisted of the addition of two new 15 KV vacuum switchgear units to the existing lineup of main service switchgear. Modifications were made to the existing main incoming switchgear units to add ampere and watt transducers and watt-hour demand meters, auxiliary current transformers (1/1 ratio) were added to provide the current source. Adding ground sensor relays, lockout relays, ammeter, ampere and watt transducers and watt-hour meter modified the existing feeder units. In one unit a series connected 50/5A CT ratio was used because of the added burden which would cause the existing 50/5A CT to saturate. The transducer outputs were wired to remote terminal cabinet for future load control. Also as part of this project two (2) 1500 KVA 12KV - 480Y/120V plant area substations with outdoor oil filled transformer were added. As part of the control scheme interlock circuits were installed from the plant area substation transformer fault pressure relays, secondary over current, and ground fault relays and control switch to trip the associated upstream 12 KV feeder circuit breaker. A complete short circuit and coordination study was prepared for this project.

ELECTRIC GRAPHITIZING FURNACES
Installation of new graphitizing and carbon facilities for Niagara Falls, New York and St. Mary’s, Pennsylvania facilities including Sagger unloader, Mill Mix, Battery Plant.
Projects involved phased construction of foundations 150 KA electric graphitizing furnaces, main 115-12KV switchgear, process gas distribution, oil quench distribution and heating, sand handling and coke drying facilities, pick up 500°F coke from furnaces by means of specially designed vacuum ware, silo loading, nitrogen driven pusher system for furnace heads, and cutting machine to square off 36" O electrodes, fume handling and monitoring, platforms, stack installation, aircraft lighting, flour mix systems, extruder and other materials handling and weighing systems. Ancillary facilities were also designed to house electrodes, manufacturers and repair sagger cans, side blocks maintenance and repair facilities for hydraulic components. shipping and receiving and office facilities were also designed.

SWITCH GEAR
This project involved a study to determine a scheme to revise the existing relaying and interlock/lockout control circuits to the plants’ main incoming 115 KV switchgear to prevent spurious trip out. The interlock/lockout control circuitry was interfaced with remote trips of two control circuits from West Penn Power Company. New formal asbuilt drawings were prepared and turned over to the owner.

AIR BALANCE DESIGN
Relocation of induced draft fans for a general plant renovation project. Fans were relocated from the upstream side of the electrostatic precipitators to the downstream side. The motors were refurbished and space heaters were added to prevent moisture damage to the motor windings.
Monitoring of motor bearing and winding temperature and bearing vibrations were added. The boiler house controls were revised. All 2400V electrical distribution (cables, feeders, fusible feeder switches, motor starters, etc.) were upgraded.
The air balancing was revised and the ductwork was redesigned and reinforced to accommodate the change in operating pressure. Existing ductwork, which had been designed for external pressure, was reviewed for internal pressure. New ductwork support hangars and expansion devices were designed. Structural steel support towers were required, as well as detailed design of expansion joints and installation of 8’x10’ breaching. The ductwork was designed for 300°F.

MILL DRIVE CONVERSION
This project involved the conversion from 25 HZ to 60 HZ of a 2400V 300 HP wound rotor 21" mill drive. The 60 HZ conversion work consisted of the installation of a new 12KV feeder in cable tray to a new 5000 KVA 12KV – 2400V high resistance grounded neutral outdoor oil filled transformer. Oil containment was provided for compliance to EPA requirements due to close proximity to waterways. A 2400V feeder in conduit was run overhead on a conduit bridge to the existing motor controller. The existing controller was modified to replace existing watt-hour demand meter, recording wattmeter, thermal-overcurrent relays, phase sequence and underwattage relays and current balance relays. New control wiring was installed to new resistance thermal device and differential relays at the motor. The existing control room was expanded to install new secondary resistor banks. A short circuit and coordination study was conducted to evaluate motor protection and starting.

PLANT MODERNIZATION
This project involved the complete modernization of the entire plant. This involved analysis of existing production procedures and production equipment while making recommendations and providing detailed engineering for new process equipment.
This contract included both major and minor modifications to their existing plant and new production building and laboratory facilities. It included all engineering phases from initial concept through feasibility study, preliminary equipment capital appropriations requests, detailed engineering, contract documents, with construction supervision and construction management on selected segments. Projects involved reheat furnaces, machinery and milling, bar-mill installation and run-out table installations, hydraulic systems and other systems for specialty steel operations.

ELECTRICAL DISTRIBUTION
This project included reviewing the electrical distribution system using a high resistance ground style system vs. a Delta-Delta system. The entire plant electrical system was reviewed for fault currents and system coordination. A five-year construction program was established for upgrading the distribution system. This included scope definition for construction packages and cost estimates for capital appropriation requested. An analysis of NFPA code violations was prepared and costs of rectification were estimated. Hazardous areas were reviewed.

OVERHEAD POWER DISTRIBUTION
Study to install a new 34.5 KV overhead distribution pole line system approximately 4599’ in length across the plant complex. This study consisted of a field survey to select a route while considering clearances over railways, roadways, process piping system bridges and existing 12 KV aerial system and method of termination at an existing substation structure. A site plan was prepared indicating the selected route along with pole location and guy locations. A construction budget estimate was also provided.

SPRINKLER ALARM SYSTEMS
Approximately 200 buildings to be covered by a sprinkler alarm system. In an ongoing arrangement to design multi-zone systems with sprinkler tie-in, new water flow switches, smoke detection, heat detection and anti-vandalism manual stations with separate trouble annunciation over a separate plant wide supervisory system. These system designs have involved box and signal circuit revisions to manufacturers equipment which have required an in-depth knowledge of not only the code requirements, but also the actual operations of fire alarm system components.

MACHINE RELOCATION
This project for the General Electric Company involved approximately 750 machines being relocated in two buildings. The machines were primarily metal working machines including presses, brakes, lathes, drills, automated punches, paint spray, and shot blast booths, paint spray lines, acid dip, plating, numerical control milling, etc. Various types of interface were required for centralized computer process control and material flow, as well as revised service connections. All utilities were surveyed since the relocations and additional machines expanded the process requirements. Additional air, steam, water, drain, oil, sewer, and acid services were required. Increases in electrical power and distribution systems were provided. Control revisions were made to comply with metal working machinery (NFPA 78) requirements. We designed trenches, machine bases, building additions, lighting, fire alarm, computer facilities and all services to suit the machine and process installation and to suit further expansion.

LOCOMOTIVE TEST CAR
This project involves the design of a new rolling stock test car in a 1946 stainless steel Budd Passenger Coach. Design work includes placement of instrumentation, racks, portable and desktop computers as well as design of living quarters and recreation space for extended living. All must operate in environment of -40°F to +150°F for extremes in the North American continent. Work involves space planning, interior design, mechanical and electrical systems, electronics and shielding as well as on-board prime power, fresh water and waste holding, diesel fuel storage and air brake and locomotive control.

AUTOMATED PUMPING SYSTEM
In general, the project scope electrically involved the design of control system utilizing remote control stations and a central control programmable controller with a central status and control panel. The programmable controller was installed in the electrical room which provided it with a suitable environment. The main or central panel was installed in the wing on the second floor, as dedicated by the process. The panel had graphic representation. At connection point there is a local panel which indicated the status of the system and enables the user to set up the system to pump his spent solvent. Valve control interlocks were also interfaced at this point to isolate the local pump from the main system if another area is presently using the system. The main panel indicates the status loadlugger and also locks out the pumping system if the loadlugger is full. Interlocks to the building evacuation system were provided to shut down the system on alarm or if building sprinklers or the load lugger pad deluge system is activated. Grounding of the various system components and the loadlugger area was provided to Kodak's standards. New lighting was provided at the loadlugger area and at the central panel location. In other areas the lighting, paging and miscellaneous systems were relocated to accommodate the new pumping system piping. The electrical engineering work included all the design documents, estimates, P.C. hard copy, tape dump, equipment economic evaluations, bid specifications, and quality releases in accordance with Kodak's standards.

TRANSFER & PACKAGING SYSTEM
The transfer system conveyed atomized polyethylene by negative pressure and diced. This project involved the installation of a new (dual) product transfer system and packaging equipment polyethylene over 400 ft. from the existing production area to the new packaging equipment. New packaging systems/lines were provided for both the diced and atomized products.
Valve-Pack bags were automatically filled with product, labeled, check weighed, palletized and stretch wrapped. This system approximately tripled the output of the original manual packaging equipment. In addition to reducing manpower requirements by half, the new systems provided for quality control and a finished product not previously possible.

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