3 SAFETY AND RISK MANAGEMENT Management, Facility Assessment, Engineering and Training Risk and Hazard Assessment • Program requirement development • Facility hazard assessment including OSHA’s safety, fall protection, electri- cal, hygiene, fire and explosions. • Facility services assessment and design including water, storm, sanitary and process sewers, natural gas, electricity, steam, lighting and chemical sup- plies. • Equipment selection for facilities meeting ASME, ANSI, NFPA, ASHRAE, JCAHO, BOCA, VA, FDA, ISO, OSHA, DEA, HUD and EPA regulations • Construction Cost Estimates & Capital Appropriation Requests • Energy Cost Reduction, Process Optimization Programs for support equip- ment Safety Engineering Design • Piping, • Mechanical, and Pollution Control • Structural, • Civil, • Electrical and Controls Safety Program eTraining Solutions & Operational Support • eTraining Solution Suite for Management of trainees • Coursework development • Safety Job Procedures
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3
SAFETY AND RISK MANAGEMENT
Management, Facility Assessment, Engineering and Training
Risk and Hazard Assessment
• Program requirement development
• Facility hazard assessment including OSHA’s safety, fall protection, electri-
cal, hygiene, fire and explosions.
• Facility services assessment and design including water, storm, sanitary and
process sewers, natural gas, electricity, steam, lighting and chemical sup-
plies.
• Equipment selection for facilities meeting ASME, ANSI, NFPA, ASHRAE,
JCAHO, BOCA, VA, FDA, ISO, OSHA, DEA, HUD and EPA regulations
• Construction Cost Estimates & Capital Appropriation Requests
• Energy Cost Reduction, Process Optimization Programs for support equip-
ment
Safety Engineering Design • Piping,
• Mechanical, and Pollution Control
• Structural,
• Civil,
• Electrical and Controls
Safety Program eTraining Solutions & Operational Support
• eTraining Solution Suite for Management of trainees
• Coursework development
• Safety Job Procedures
4
Process and Flammability Hazards
• Fire and Explosion hazards
• Chemical Exposure hazards
• Toxicity Release hazards
• Piping and equipment maintenance and change out
• Review of gas monitoring and hazardous notifica-
tion systems
• Review and assessment of Emergency response sys-
tems
Fall Protection
• Permanent Structures
• Platforms, flooring, Swingates, guardrails,, toe-plates, access and
emergency ladder systems
• Temporary and Construction Structures
• Lifelines , harnessing and anchoring devices
• COTS solutions or engineered customization
Electrical Hazards
• Bonding and grounding
• Electrical enclosures assessment for hazardous
conditions realated to moisture, dust, and explo-
sive mixtures
• ARC/Flash hazards
• Overloaded circuits
• Electrical cable and conduit routing
• Labels
• Short circuit calculations and assessment of current-limiting graduated response
for electrical fault in the facility
Workplace Design and Ergonomics
• Accessibility of normal and emergency apparatus
• Work space review for posture, fatigue and stress
related factors
• Loading and unloading hazards
• Maintenance practices
• Information displays
• Warning lights and labels
• Training and COTS solutions
Hygiene
• Investigation and review of existing systems for improvements in contamination
control, ventilation and Clean Room design
• Equipment selection for hands free design and operation
• Cleanable surfaces and porous free materials
RISK AND HAZARD ASSESSMENT
6
SAFETY ENGINEERING DESIGN SERVICES
Electrical:
Power systems 2.4 KV, 480 V and 110 V
Secure Systems
Emergency and Backup including Diesel Generator with ATS
Lighting
VFDs, Motors, and Drives
Environmental Control
Airborne Contamination Controls
Waterborne Contamination and Purity strategies
Infection Control Methodologies
Hazardous Collection and design.
HVAC, Industrial Ventilation
Investigation and review of existing systems for improve-
ments in contamination control, ventilation, heating, air
conditioning
HVAC system design including chillers, AHU’s, con-
densing units, fans for supply air, outdoor air, exhaust air,
1. 1910.119(c) - Employee Participation • Employers to involve employees to participate in the PSM program.
• Written plan of action for implementing employee consultation on the development of process hazard analy-
ses and other elements of process hazard management contained within 1910.119.
2. 1910.119(d) - Process Safety Information • Employers to develop and maintain Process Safety Information about the technology, process and material
of the covered substance. Process information that can assist in the identification, management and control
of hazards. A written plan of action and record of equipment
3. 1910.119(e) - Process Hazard Analysis • Employers to conduct Process Hazard Analysis and identify, manage and control hazards.
4. 1910.119(f) - Operating Procedures • Provide clear instruction for conducting activities involved in covered processes that are consistent with the
process safety information.
• The operating procedures must address steps for each operating phase, operating limits, safety and health
considerations, and safety systems and their functions.
5. 1910.119(g) - Training • Employees and contractor employees understand the nature and causes of problems arising from process
operations, and increases employee awareness with respect to the hazards particular to a process.
• Initial Training, Refresher Training, and Documentation.
6. 1910.119(h) - Contractors • Employers who use contractors to perform work in and around processes that involve highly hazardous
chemicals to establish a screening process so that they hire and use contractors who accomplish the desired
job tasks without compromising the safety and health of employees at a facility.
7. 1910.119(i) - Pre-Start up Review • Employers to perform a pre-startup safety review for all new installations and for significant modifications.
8. 1910.119(j) - Mechanical Integrity • Assure that equipment used to process store, or handle highly hazardous chemicals is designed, constructed;
installed, and maintained to minimize the risk of releases of such chemicals.
9. 1910.119(k) - Safe Work/Hot Work Permit • Require employers to control, in a consistent manner, non-routine work conducted in process areas. Specifi-
cally concerned with the permitting of hot work operations associated with welding and cutting in process areas.
10. 1910.119(l) - Management of Change • Requirement for management of all modifications to equipment, procedures, raw materials and processing
conditions other than "replacement in kind" by identifying and reviewing them prior to implementation of
the change.
11. 1910.119(m) - Incident Investigation • Employer is required to investigate each incident which resulted in, or could reasonably have resulted in a
catastrophic release of highly hazardous chemical in the workplace. An investigation shall be initiated no
later than 48 hours following the incident.
12. 1910.119(n) - Emergency Planning and Response • Require the employer to address what actions employees are to take when there is an unwanted release of
highly hazardous chemicals.
13. 1910.119(o) - Compliance Audit • Require the employer to certify every three years compliance with all the sections of PSM standard.
14. 1910.119(p) -Trade Secrets • Require the employer to ensure that Trade secrets do not impede exchange of information related to safe
operation of the facility.
Process Safety Management Program
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
1049
BOF Hood Cooling Engineering, 360 Million BTU/Hr Cooling System upgrade including fan, VFD, piping and controls Engineering and Equipment Design
I,III,IV,V
Indiana
Fall Protection: Accessibility platforms, non-slip gratings, safety toe-plates, handrails Electrical: temrminations, ANSI enclosures, and explosion proof ratings
2,000 2010
1035
GI 8 East Upgrade at Richard L Roudebush VAMC Hospital, Indianapolis
I, II, III, IV, V
Indiana
Fall protection, electrical and ergonomic issues related to the design of a 10,000 sq ft GI clinic in a 10 story hospital. Ergonomics included design of manual cleaning and sterilization stations with comfortable working access and posture for a wide range of healthcare workers. Hygiene including "hands-free" operation of sinks and toilet facilities. Stainless steel fixtures and materials for easy cleaning. Included adjustable sinks heights, pass through windows with access, heavy patient load considrrations. Fall protection included platforms of Air Handling Unit at roof top. .
2,000 2011
1037
Building 6 Renovation at Aleda E Lutz VAMC Saginaw, Michigan
I, II, III, IV, V
Michigan
Fall protection, electrical and ergonomic issues related to the design of mechanical systems. Hygiene including "hands-free" operation of sinks and toilet facilities for a converted boilerhouse.
4,500 2011
1046
Chlorine Monitoring III,IV
Indiana
Review, make recommendations and equipment selection for the customers chlorine gas hazard monitoring system. To include additional monitoring devices and communication to a central notification system and the utilties dispatch and fire department dispatch center. Intergrate the two systems in to the plants emergency response system.
100 2011
1043
Chlorine Process Hazard Analysis (PHA)
III,IV
Indiana
29 CFR 1910.119 OSHA PSM Process Hazard Analysis. Safe handling of 2-ton chlorine cylinder with a catastrophic risk radius of 1.3 mile. Mitigation strategies with alrams, training, operating procedures and additional handling devices.
500 2010
1042
Chlorine P and I D III,IV,V
Indiana
Process Safety Management to update and generate nine chlorine site facility process and instrumentation schematics as well as locations for safety equipment and functioning. Installation review, operations analysis. Liquid Chlorine used: evaporators, chlorinators, eductors, process water, solution water. Chlorine Gas used: chlorinators, eductors, process water, solution water
30 2010
1041 Chlorine PSM Compliance Audit / Assessment
I,III,IV,V Indiana Review and update of the costumers PSM program, questionaire and operating procedures. 15 2011
1040
BOF - Caster Project Management
I,II, III,IV
Indiana
Fall protection, electrical and ergonomic issues related to the design of Material Handling system related to transfer of raw material at 200 ton / hour. Included review of load stations, maintenance platforms and accessibility requirements.
25,000 2011
USGSDOI- US Geological Survey -LMERS - National Park Service
II, VIndiana
The feasibility study required assessment of fall protection features for conversion. Ergonomics issues related to laboratory design, work stations and handling procedures for a a Class III
50 2011
1022Security Upgrade - Outpatient Pharmacy and Agent Cashier
II,III, IVIllinois
Upgrade security systems and additional features to include cameras, windows, reflected ceiling relocating and wall relocation
600 2010
1039
LMF Engineering, piping and controls Engineering and Equipment Design
I, II, IV,V
Indiana
LMF Hot Well water system drainage study, engineering design
2,000 2010
1034
Consolidate Scope Sterilization at Richard L Roudebush VAMC Hospital, Indianapolis
II, III, V
Indiana
Ergonomic assement and mitigation included design of sterilization stations, pass through windows, height of sinks, contamination challenges combined with weight and ergonomics considerations
500 2010
1044
BOF - Caster Project Management - Ergonomically designed trolly
I,III,IV,V
Indiana
Ergonomics: Assessment and implenetation design of manual-trolley around hazardous molten steel in limited confined space. Bending and turning stresses, load distribution to permit low center of gravity and prevention of flipping hazard.
30,000 2010
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
1032
Storm Sewer Drainage System for BOF at Steel Mill
Indiana
Provide Design Concept drawings to include sewer manholes, drain piping and perforated french drain piping to take care of constant flooding issues between the BOF and Caster facilities. 250 In progress
981Process Safety Management - Propane System Coordinator
Provide Analysis on FAA facilities for energy reduction and conservation. Recommend Energy Conservation Measures related to light occupancy changes, operation of chillers, Air Handling Unit modifications, Pump modifications. Cooling tower operations
120 2009
1030
Electrical Upgrade - Buildings 58, 98, 104
III, IV
Illinois
Hazards asseemment and mitigation included existing access and electrical issues, ground and fault protection issues and mitigation strategies by coordination studies, fencing and proper classification of equipment installation.
1,100 2009
1031
Structural Evaluation and Analysis Building 103
III, IV
Illinois
Electrical hazard assessment after a fire. Provided evaluation and analysis of the structural integrity and make recommendations in the form of a report to the VA for Building 103, Nursing Unit No. 4 Mechanical Room which was damaged when the electrical transformer outside the south end of the building caught fire. Inspection included roofing and insulation, wall and roof framing and review of the structural drawings
100 2009
1031
PHA Analysis Sessions for Co-Generation Plant under construction
I,III,IV,V
Illinois
Fall protection assessment included valves access and platforms, electrical hazards during maintenance and operation and ergonomical considerations for equipment maintenance and removal. and piping review,
18,500 2009
1033
Emergency Department addition to building 58
II, III, V
Illinois
Electrical and ergonomic issues related to the design of a 9,000 sq ft Emergency Department. Ergonomics issues were combined with security consideration during late hours and included design of manual transfer of patients from the ambulances, heavy patient load considrations and lifts. Hygiene included fixtures and sink "hands-free".
3,000 2009
990-05BOF Stack Replacement and Upgrade - Engineering detail design
I,III,IV,VIndiana
New stack shell design, access platforms, ladders, Gas flow measurements, electrical and lighting, lifeline and fall protection anchors
1,500 2009
ABE-01Columbarium Expansion - Abraham Lincoln National Cemetery
IIIllinois
Hazard assessement and abatement included falling and slipping hazards around adjoining creek, cleanable, yet non slip walking services. Height of niches for access.
2100 2009
1021
SPD Suite - HVAC and Pure Water System Upgrade
II,III,V
Illinois
Air borne Contamination Control: Upgrade of HVAC, Operational objectives with Energy cost sensitive approach. Ventilation, heating system, chilled water system. Pure Water system: RO unit, Circulation system
400 2008
1020
New Storage Building with multiple truck bays including electricity, lighting and heating. New Soil Pit design to replace for ground maintenance soil storage at Cemeteries (Design-Build)
II,III,IV,V
Kentucky
Site layout, sewers, foundations, block framing, overhead doors, Electrical, fire hydrant, roof, Fire Detection
420 2008
997
BOF Alloy Feed Conveying System - Engineering Study Design. Bin sizing, equipment specifications and Request for Proposal
II,III, V
Indiana
Site Utilities, Equipment Layout, Furnace chutes, structural floor layout, electrical, controls, weigh belt feeders, alloy feed receipt
21,000 2008
1014Fuel Loading Station - Engineering Services (Detailed Design
I,II,IV,Indiana
Assessment and mitigation fuel loading stations and loading considerations including fall protection and electrical ground safety.
750 2008
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
1015
Engineering Services for Natural Gas Mixing Station to supply in the case of an emergency to Coke Oven Gas Main Pipe Line - Design and installation
Engineering Services to provide ETRAINING for operators and maintenance personnel at LMF Water Treatment Plant
I,III,IV
Indiana
Training courseware design and implementation.for operations and maintenance.
50 2008
1023PHA Analysis Sessions for Co-Generation Plant,
I,III,IV,VIllinois
Hazard Analysis, risk analysis, Energy usage review and reduction, new Power Plant facility design process and piping review,
15,000 2008
1016
BOF Hood Cooling Engineering, 360 Million BTU/Hr Cooling System upgrade including fan, VFD, piping and controls Study and Equipment Recommendations
I,III,IV,V
Indiana
Hood Cooling water system monitoring, heat exchanger fans, Air humidity and speed recording, BOF Furnace consumption
2,000 2007
990-01
Electrical Upgrade, NEC Violations, 5 hospital buildings and complex, 200,000 sq ft area
III,IV Illinois
Hazard mitigation per NEC rules compliance. Mitigation strategies included: Electrical conduit overfill, new panel, conduits, clearances, tap violations, grounding procedure, support of electrical equipment and heat removal issues.
500 2008
1013
Engineering Study and Equipment Recommendations for Pickle Line Strip Surface Inspection System
I,IV,V
Indiana
Pickle Line existing utilities field and drawing surveys, piping modifications, equipment modifications new equipment installation 700 2006
1012
Engineering Study and Recommendation for Pickle Line Fume Exhaust System Upgrade and Replacement - Environmental Controls
I,IV,V
Indiana
Pickle Line existing utilities field and drawing surveys, piping modifications, equipment installation, demolition
2,500 2006
996Air Compressor Upgrade Engineering Study, Design and Installation
III,IVIndiana
Site Utilities, Water , natural gas, sewers, foundation pad, electrical, demolition, Air Reservoir tanks, piping, silencer 2,500 2006
GAF-01
GAF piping and valve stations replacement and upgrade - Engineering study and piping installation design
New Storage Building with multiple truck bays including a washbay, site utilities, natural gas, electricity, water, sanitary and storm sewers ( Design-Build)
II,III,IV,V
Illinois
Site Utilities, Water,natural gas, sewers, foundation, framing, brick exteriors, insulated, Electrical, HVAC, roof, Fire Detection
400 2006
GAF-02GAF Materials - Engineering Construction Management
IV, VIndiana
Assessment and mitigation of tank car loading considerations including fall protection and electrical ground safety. 400 2008
976 Gas Cleaning System review for damper operations and furnace control for two-furnace operations for increased productivity
I, III, IV, V Indiana Scrubber, Venturi, Waste Water Treatment,Electrical, HVAC, CO Detection and Suppression,
989-01 BP Propylene Facility - Engineering Services
I,II, IV, V Indiana Tank - decompression and cleaning 15 2006
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
990-01-02BOF Stack Replacement and Upgrade - Study design
I,III,IV,VIndiana
Foundation and structural assessments, current gas flume assessment, new stack reinforcement design, access platforms, ladders and stairs, Gas flow measurements
1,000 2006
975 Engineering study that surveyed and identified savings in complex of 400,000 lb/hr of steam system with 10,000 ft of steam piping.
IV, V Indiana Site Investigation, Survey Documentation, Report Development
200
2005
976 Commissioning Services for a Light Oil Loadout Station Upgrade, including new operator panel, flowmeter & vapor recovery system
I, III, IV, V Illinois Checklist Development, Operator Training, Troubleshooting, Electrical, HVAC, Fire Detection, Fire Suppression
800
2005
978 New Boilerhouse Utility Piping, Four(4) 150,000 lb/hr of Steam at 900 psig including coke oven gas, natural gas, instrument air (IA), nitrogen (N2), potable water & service water with supports & tie-in locations - Detailed Design
IV, V Indiana Process Tie-In, N2 / IA Switchover Station Design, Multi-Team Coordination
25,000
2005
960-04 2500 GPM Emergency Water System for an industrial plant, including tie-in into existing water supply, pumping & recirculation piping, pump controls & fuel oil tank conversion to water service - Detailed Design
I, III, IV, V Indiana Pump Selection, Control Scheme Development, Tank Modifications, Piping Design
1,000
2005
963-01 Etraining System for Process Heater and Gas Cleaning Systems at a Sinter Plant, modules
I, III, IV, V Indiana Process Review, Site Walkdown, Module Development
120
2005
966-2 Two(2) 39,000 cfm Fume Exhaust Systems for Process Line, including scrubber & fan specifications, hood & ductwork designs - Detailed Design
I, III, IV, V Indiana Equipment Layout, Hood & Duct Design, Lifting Mechanism & Building Designs, Electrical, HVAC, Fire Detection, Fire Suppression
1,200
2005
975A Pre Carbon Facility - Fuel Change over - COG Distribution Analysis, Suitability Review and Facility Definition for six(6) 60 MM BTU/HR Coke Oven Gas Trains.
I, II, V Indiana Coke Oven Gas Piping, Tie-In Locations, Energy Savings Evaluation, Electrical, HVAC, roof, Fire Detection, Fire Suppression
2,500
2005
976-02 Engineering Services for new electrically driven, 15 HP pumps with platform & piping for a chemical loadout station - Detailed Design
977-02A New Boilerhouse Desuperheated Water Generation, including reverse osmosis skids, 1st Pass 1000 gpm, 2nd pass 100 gpm, tank, & transfer pumps, deaerator with controls & interconnecting piping - Detailed Design
I, III, IV, V Indiana Foundations, Space Utilization, Control Scheme, Piping Installation, Electrical
1,200
2005
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
984-01Cross Country Oil Line system, 4000 ft, steam heated
I, III, IVIndiana
Flexibility, loops, control system, multiple users2,000 2005
960 Engineering Study and evaluation of a 110,000 GPM Cooling Water System, including system replacement scenarios & Emergency Pumping System
Indiana Pump & Driver Selection,
10,000
2004
972 Feasibility Study for a heating station roof conversion from an open loop cooling system to a closed loop cooling, 100 MM BTU/hr system
I, III, IV Indiana Envelope Determination, Existing Utility Evaluation, Calculations, Electrical, HVAC, roof, Fire Suppression
1,000
2004
956-2 Chemical Loadout Station Vapor Recovery Upgrade, including vapor recovery, plc controls, utility piping & loadout platform - Detailed Design
III, IV, V Illinois Valve Station Design, Pipe Routing, Structural Platform Design
800
2004
959-1 Engineering Study for new air compressor facility at a Pickling Line, including site walkdowns, drawing research and flow measurements
IV, V Indiana Compressor Selection, Equipment Location Scenarios, System Evaluation
700
2004
959-2 New Air Compressor Facility for a Pickling Line, including 2 x 2000 cfm compressor station layout, selection, control scheme development and piping layout - Detailed Design
I, III,IV Indiana Structural Base Design, Piping & Support Design, Power Tie-In Location, Electrical, Fire Detection
700
2004
960-02 Engineering Study and evaluation of a 100,000 gpm Plant Water System, including taking and analyzing flow measurements
Indiana Plant Water System Walkdown, Flow Measurements, Piping Replacement
10,000
2004
965-1 & 965-2
Etraining system for Hot Strip Mill Operations & Maintenance
IV, V Indiana Module Development, Process Review, 100
2004
966-1 Two (2) 39,000 cfm Fume Exhaust System for Electr Tinning Lines, including scrubber & fan specifications, hood & ductwork designs - Conceptual Design Study
III, IV, V Indiana Equipment Location Scenarios, Utility Tie-In Determination, Duct Routing Selection, Electrical, HVAC, Fire Detection, Fire Suppression
30
2004
970-01 Process Safety Management & Training Services for a chemical loadout station upgrade
I, II, V Illinois Training Manual Development, PSM Plan Modification
80
2004
QBOP-1 Training System update for a Q-Bop Propane System, OSHA required
IV Indiana Module Update100
2004
945 Gas Cleaning Stack Performance improvement, review and recommendations for the gas cleaning system
I,IV Pennsylvania Process Review, Report Development
2,000
2003
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
I, IV Indiana Process Evaluation, Piping Modifications 3,000 2003
948 Computer Based Training for 2000 scfm Fume Exhaust System Upgrade at a Chrome Plating Facility
I, III, IV Indiana Graphic Design, Module Development, Classroom Training
1,000
2003
950 Drawing Revisions for power generation facility
III Illinois Electronic Document Management, CAD Work 10,000 2003
952 PSM Administration for a propane system at Q-BOP
I,IV,V Indiana Classroom Training Sessions, Audit Performance10,000
2003
953 Engineering Study of Hood Cooling Water system for a two (2) molten 285 Ton Furnaces
I,II Indiana Data Gathering & Evaluation, Report Development
2,000
2003
927A Oxygen System Upgrade for a Building Including new oxygen control stations, piping, alarms & controls - Detailed Design
II,III,IV Illinois Alarms, Power & Control Wiring, Oxygen Piping, Site Preparation, Electrical, HVAC, Fire Detection
500
2003
956-1 Conceptual Study for a Chemical Loadout Station Vapor Recovery Upgrade, including location selection, tie-ins for new utilities and Control Panel Location
IV, V Indiana Stress Calculations, Equipment Installation, CAD Drawing Development 100
2002
944 As-Built Drawing Documentation for a power generation facility
III Illinois CAD Work, Drawing Management10
2002
922-2 Compressor Facility, Including Compressors (2000 cfm x 4), Dryer, Receivers (2 x 15,000 gal.), Piping Modifications & Control Systems - Detailed Design
I, III,IV Indiana Compressors, Dryers, Receivers, Location Selection, Piping, Electrical, HVAC, Fire Suppression
2,000
2002
922-3 Computer Based Mechanical & Electrical Training Programs for Air Compressor Facility Operation & Maintenance
III Indiana Training Program Development
50
2002
927-1,2 Chrome Line Plating Solution Temperature Control for improvement in yield and quality
IV Indiana Piping Design,Equipment Selection, Process Calculations
300
2002
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
MG-1 Precipitator Penthouse Seal Air System Replacement
I,II, IV, V Illinois Site Review, Data Gathering & Review, Report Development100
2002
VA-Danville
(925)
2300 cfm HVAC Unit & 350 Ton Chiller Upgrade for Buildings 98 & 101 at a VA Hospital - Detailed Design
I,III,IV Illinois Power & Control Wiring, HVAC Selection & Installation, Site Preparation, Electrical, HVAC
600
2002
VA-Saginaw
(928)
Medical Air System Upgrade for a VA Hospital, including compressor installation & piping modifications - Detailed Design
II,III, IV, V Michigan Alarms, Power & Control Wiring, Medical Air Piping, Equipment Installation, Electrical, HVAC, roof, Fire Detection, Fire Suppression 300
2002
888 QBOP Computer Based Training Program for Propane Facility Operation & Maintenance Departments
I, IV Indiana Training Program Development
30
2001
903 Dust Emission Control for Industrial waste recycling plant - Engineering Study
IV Indiana Temperature Measurements, Process Review1,200
2001
905 QBOP Process Safety Administration for a Propane System at a Integrated Steel Mill
IV Indiana Data Organization
1,000
2001
917 New 8000 cfm Air Compressor Facility Location for a Tinning Line - Study
IV Indiana Facility Location Selection, Utility Tie-Ins, Usage Requirements
1,000
2001
918 UV Light Installation for Coating Line - Detailed Design
II,V Illinois Web Path Modifications, Structural Calculations25
2001
920 Control Valve Relocation & Piping Modifications for a Rolling Mill - Detailed Design
II, III Indiana Piping Design, Outage Requirements, Electrical
10
2001
921 New 10,000 sf Coating Facility As-Built Documentation
III, IV Illinois Site Measurement & Documentation10
2001
923 Industrial Facility Effluent Monitoring Station - Detailed Design
III, IV Indiana Equipment Selection, Process Review50
2001
924 QBOP USS-GW - QBOP Propane Facility CBT
III, IV Indiana Module Review, Program Modifications 10,000 2001
890-10 Bubbler Tank Design for a Pickling Line Fume Exhaust Upgrade
I, III, IV Indiana Tank & Piping Design50
2001
890-12 OWTP additional engineering services
IV Indiana Process Review 2,500 2001
890-13 Engineering Services for Waste Treatment Facility
IV, V, VI Indiana Portable Tank & Pump Selection, Vendor Coordination 2,500 2001
890-14 Fume Exhaust System Engineering Services
IV Indiana Process Modification, Data Gathering 2,000 2001
II, IV Indiana Process Evaluation, Piping Changes2,000
2001
890-8 66" pickle line fume exhaust additional engineering services
II,III, IV Indiana Piping Design, Electrical1,200
2001
890-9 75" pickle line fume exhaust additional engineering services
IV, V Indiana Process Site Review1,500
2001
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
903A Gas Cleaning System Upgrade and replacement of scrubber with a 280,000 acfm baghouse - Engineering Study & Conceptual Design
III, IV Indiana Baghouse Location, Foundation Design, Electrical Power Requirements
5,600
2001
922-1 Compressed Air, 8000 scfm, 3000 lf, 8" dia. plant wide system. Investigation for Energy Savings and New Compressor Facility Planning - Engineering Study
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
853 Galvanizing Line Air Knife Nitrogen Wiping System Installation - Piping and support design, reducing and flow control stations, Detailed Design
IV, V Indiana Valve Stand Design, Pipe Routing, Electrical, Fire Detection, Fire Suppression
750
1999
860 Steam-based Hot Water Supply for 200 persons - Study
Indiana Heat Exchanger Evaluation400
1999
863 Plant 4,000,000 BTU /Hr Gas-Fired Hot Water Heater Installation - Detailed Design
IV, V Indiana Hot Water Heaters, Piping Design, Electrical, HVAC, Fire Detection, Fire Suppression 250
1999
864 Sheet Mill compressor upgrade, Demolition Plan & Detailed Design
IV, V Indiana Equipment Sizing, Equipment Layout, Utility Search1,100
1999
866 75" Pickle Line Acid Rinse Water Flow Restriction Study
IV, V Indiana Piping Layout20,000
1999
871 Sinter plant air emissions upgrade, improved hood design, breaker end separator upgrade
IV, V Indiana Site Walkdown, Process Design, Equipment Modifications
1,000
1999
872 BOF Command Tower Sewage and Mill Water Lift Stations - Detailed Design
IV, V Indiana Lift Stations, Piping Layout, Electrical
200
1999
874 5 stand water conditioning for 300 GPM Shape Control System - Study
IV, V Indiana Equipment Selection, Plant Hook Up, Equipment Location, Process Investigation 1,100
1999
875 Construction & Commissioning Assistance for a QBOP Propane Supply System Installation including Scheduling, Construction Review, Expediting, Testing, Factory Acceptance Tests, Commissioning Benchmarks, Operator Interfaces
IV, V Indiana Commissioning, checkout and scheduling
2,500
1999
879 Performance Improvement for Air Knives coating plant - Instrument Air conversion to Nitrogen Detailed Design
Indiana Pipe Sizing, Pipe Routing
2,000
1999
880 Vacuum Generating Process, Contact Cooling Water Treatment Study
IV, V Indiana Water Sampling, Data Review1,000
1999
895 Remote Annunciation and Control for Air Compressor Installation - Detailed Design
IV, V Indiana Control Wiring, Power Wiring, Electrical
IV, V Indiana Commissioning, checkout and scheduling
1,700
1999
882-2 Manufacturing Facility - Adhesive Delivery System - Detailed Design
IV, V Indiana Piping Design, Equipment Location, HVAC, Fire Detection15
1999
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
897util Plant wide study of Boiler and Cogeneration system for operation and hazards in a 1,500,000 lb/hr steam eight boilers, 150 MWe electricity system HAZOP study for TurboBlower BoilerHouse
IV, V Indiana Report Development, Sitework, Electrical
2,500
1999
903-2 200,000 scfm Gas cleaning system with venturi scrubbers, cyclonic separators and a 2500 gpm circulating water system. -Study
IV, V Indiana Site Investigation, Vendor Contacts, Report Preparation, 6000 Hp Motor Review
808 BOF Dust Transfer, bulk material handling system
IV, V Indiana Baghouse Location, Duct Routing & Design, HVAC 125 1998
818 Blast Furnace Spare Parts / Modular Office Building Installation & Site Prep, 2500 sq. ft - Detailed Design
Indiana Building Design, Building Location, Utility Search, Electrical, HVAC, Fire Detection, Fire Suppression
700
1998
823 Galvanizing Line Compressed Air Supply for Air Knives - Screw Compressor Replacement with centrifugal units 3 x 3000 cfm - Study and Detailed Design
IV, V Indiana Equipment Selection, Equipment Layout, Piping Design, Electrical
2,000
1998
824 BOF Post combustion System with control and reducing stations for 4000 scfm flow rate - Detailed Design
IV, V Indiana Equipment Location, Process Development, Valve Stand Design, Pipe Routing, Electrical
3,000
1998
831 BOF Gas Quenching system enhancement with atomized air dual media spray nozzle of a 100 million BTU/hr, 2000 gpm system - Study
IV, V Indiana Nozzle Selection, Nozzle Ring Design
100
1998
834 Waste Stream Dewatering for Electrolytic tinning Line - Detailed Design
IV, V Indiana Dewatering Skid Design, Equipment / Material Selection700
1998
839 Productivity improvement of a BOF by enhancement of auxiliary feed and heat removal system, Review of Gas Cleaning System including furnace operations, hood design and cooling, induced draft fan and auxiliary systems - Study
IV, V Ohio Production Improvement
2,500
1998
841 Blast Furnace Cold Blast Mains Nitrogen purging for combustible concentration control ( 0- 3000 scfm, 80 psig, 10 changeovers system) - Study
II, IV, V Indiana Valve Stand Location,
800
1998
843 Tin Line Quench Tank Temperature Control System for strip coating quality improvement
II, IV, V Indiana Process Investigation,Technology & Equipment Selection
800
1998
845 BOF Hood Cooling Water System review to eliminate production snags - Study
I, IV, V Indiana EPA Limits, CO hazards, cooling of furnaces
50
1998
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
847 Tinning Line chemical section hot water generation as-built documentation
IV, V Indiana Equipment Documentation, Flow Diagram Development
5
1998
848 Chrome Plating Line Solution Evaporation System as-built documentation
IV, V Indiana Equipment Documentation
30
1998
852 Shower and Locker facility, 1,800 sf,- Location Study
II, V Indiana Building Layout, Utility Search, Electrical, HVAC, roof, Fire Detection, Fire Suppression 800
1998
854 1,800 sf Welfare Building Installation for Hot Strip Mill -Detailed Design
II Indiana Utility Location, Building Design, Building Location, Electrical, HVAC, roof, Fire Detection, Fire Suppression 800
1998
859 LMF Vacuum Degassing Process As-Built Documentation
Indiana CO scrubber, steam jet ejectors1,200
1998
877 6 stand oily wastewater treatment & cost reduction study
IV Indiana Process Investigation500
1998
883 Caster Tundish Handling Clearance Study
Indiana Crane Handling, Logistics design 25 1998
793 LMF Vessel Roof Water Spray Cooling System - Study
IV Indiana Cooling Tower1,250
1997
796 Upgrade Sheet Mill Plant Air Compressors and Distribution System - Instrumentation and Controls, Automatic operation and remote monitoring - Study
II, III Indiana Piping, Equipment Layout, Electrical
1,800
1997
800 Energy savings by BOF Scrap Pre-Heating Impact - Natural gas system, lance handling system
IV Indiana Concurrent Furnace Operations
15
1997
801 Continuous Caster - Emergency / Backup Air system for Air Mist Cooling - Study
IV Indiana Pipe Routing
1,000
1997
809 Office Building - Hot Water Recirculating Heating System Upgrade 5 MM BTU/Hr - Detailed Design
II, V Indiana Pumps, Piping Design, Electrical, HVAC, roof, Fire Detection
70
1997
813 Fuel Oil Transportation - Truck Loading and Unloading Stations - Study and conceptual design. 200,000 gallon per day
I, IV Indiana Unloading Stations, Truck Movement, Electrical, Fire Detection
700
1997
814 BOF - Flux Handling at Unloading station with provision for a 42,000 cfm Dust Collection System - Study and conceptual design
I, IV, V Indiana Baghouse Selection, HVAC, electrical
600
1997
816 Integrated Steel Facility Fuel Oil Pipeline 3000', 8", Lakefront to Merchant Mill - Conceptual design and cost estimate preparation
II Indiana Piping, Stanchions
2,700
1997
817 Steel Producing Complex- Upgrade Plant Air Distribution System - Study and conceptual design
II Indiana Equipment Location, Equipment Selection
100
1997
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
819 BOF - 1300 gpm Lance Cooling Water System Upgrade - Study
IV, V Indiana Pump Upgrade, Pipe Upgrade, Heat Exchanger Upgrade, Electrical 200
1997
821 BOF Gas Cleaning System Draft Monitoring of 500,000 scfm particulate laden gas - Detailed Design
IV, V Indiana Pressure Transmitter Selection, Outage Requirements, HVAC
1,000
1997
825 66" Pickle Line acid supply vent line study
II, IV, V Indiana Pipe Routing, Pipe Supporting 200 1997
827 LTV-Galv. Line Air Compressor Replacement detailed design
II Indiana Demolition Plan, Compressor Layout, Air Piping Tie-In, Electrical, Fire Suppression 1,000
1997
828 Tin Mill 5,000 gal. sulfuric acid tank replacement-detailed design
I, II, IV, V Indiana Tank Design, Pipe Material Selection1,000
1997
829 Tin line 10" steam line installation for chemical treatment section - Detailed Design
I, IV, V Indiana Equipment Selection, Pipe Routing500
1997
791 BOF Steam Injection Nozzle Relocation and Reorientation - Examination of Waste Gas Cleaning System Conditioning and Precipitor performance
IV, V Indiana Evaporator Chamber
80
1996
792 5 Stand Tandem Mill Hydraulic Oil Cooler Performance Analysis, Added 500,000 BTU Heat Exchangers - Study
IV, V Indiana Process Requirements, Heat Exchanger Location
10
1996
794 Sinter Plant Air Emissions Upgrade, Conversion of Electrostatic Precipitator to Drop-out Chamber Study
II, IV, V Indiana Drop-out Box Internals Design, HVAC
700
1996
795 5 Stand Tandem Mill Hydraulic Oil Cooler Performance Analysis, Added 500,000 BTU Heat Exchangers - Detailed Design
IV, V Indiana Heat Exchanger Selection, Piping Layout, Electrical Design
400
1996
797 BOF Hood Cooling Water Expansion/Mixing Tank Developed internal tank modifications to upgrade flow distribution and reduce residence time, and pressure drop to eliminate high-hood pressure aborts.
IV, V Indiana Tank Internals Design
100
1996
798 BOF Hood Cooling System Expansion Tank - design modification with a nitrogen blanket system. Gas Cleaning System review
IV, V Indiana Control Valve, Piping, Electrical
100
1996
799 Process Safety Management for Coke Oven Gas Desulfurization Facility, Program Development & Manual Preparation
IV, V Indiana Manual Development
10
1996
Legend: I - Fall Protection, II - Ergonomics, III - Electrical, IV-Flammability V - Hygiene
Project Number Project Title Hazard /
Abatement Location Hazard Risk ConsiderationsEst.
Project Cost
Year Complet
ed
EnerTronics Engineering Corp.
Hazard Abatement
Project Listings: Period 2008-2011
802 Slag Splash Process at Basic Oxygen Furnace - Detail Engineering relating to nitrogen system
II, IV Michigan Piping Layout, Furnace, Lance
20
1996
803 As-Built Documentation for a rolling Mill performance upgrade
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