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Xytel’s process engineering team will work with
you to convert your preliminary ideas into a potent process design.
With decades of experience, we provide services to support
fundamental research, thus enabling scale-up and commercialization
to your research ideas. Our process engineers can also help you to
fine tune your research experiments to generate required design
Xytel’s Process engineering team will support the project team throughout the project lifecycle by performing Front End Engineering Design (FEED), Detailed Engineering Design (DED), overseeing procurement & construction activities; and participating in commissioning activities.
Front End Engineering Design (FEED):
Feed or Basic Engineering is the first stage of project lifecycle. Xytel develops the conceptual design into a FEED package which includes, confirmation on conceptual design,clarification of technical issues and development of engineering documents viz. Process flow diagram, Process description with design basis, critical equipment datasheet, major equipment list and P & I Diagram. Based on these inputs, Xytel conducts HAZOP if necessary and then go ahead with detail engineering and procurement activities.
For large scale pilot plants, Xytel develops detail engineering documents and conducts HAZOP after detailing and then proceed with further activities.
Detailed Engineering Design (DED):
Based on FEED package, process engineering team performs following activities:
Equipment sizing calculations, hydraulic calculations and
relief valve sizing calculations
Prepares detailed P & I diagram, equipment specification sheet, equipment list, relief scenario specification sheet, utility consumption summary, tie-in point list and cause and effect diagram.
Take part in HAZOP study, graphics development and layout development.
Process team uses long-term or short-term licensed commercial process simulation software (CHEMCAD) and/or in-house simulation programs to perform:
Detailed mass and energy balances, Unit operation design/evaluation, piping system hydraulics calculations, Relief system design/evaluation and Heat exchanger design/evaluation
Procurement, Construction and FAT:
Review of documents received from vendors and make sure that procured items matches required specifications
Co-ordinate with construction team and assist in matching additional process requirements
Perform factory acceptance testing of the unit at our premises
Commissioning of the unit takes places at client’s location with actual chemicals.
Process engineering team assist in Identifying loops for pressure testing Performing mechanical completion Pre-commissioning and commissioning activities.
Operation and Maintenance:
Process engineering team also supports in Process evaluation, troubleshooting, optimization, debottlenecking, Operator and technical staff training
Xytel’s Mechanical team has the capability to perform advanced engineering activities / studies like,
Xytel has considerable experience in the design and manufacture of pressure vessels,Heat Exchangers, reactors and autoclaves to match specific requirements.
All our vessels are fully ASME-compliant, and are designed in accordance with recognized codes such as API and ASME VIII.
We work with a wide range of metallic materials, from low alloy steels to exotic high-nickel alloys – with surface treatments where necessary – as well as glass, plastics and fiber composites.
Bench Top, Skid and Pilot Plant Design:
We start by reviewing where the plant will be located and understanding your space constraints.
For pilot plants and skid units, this could either be an internal or external location. Bench top units are usually located within an extracted enclosure either self-contained or in a fume cupboard.
Large components such as vessels and pumps are then modelled and laid out in accordance with the P&ID and their operating parameters, e.g. head requirements for pumps, straight pipe runs for flow meters, etc. The framework is then modelled around the components, providing the necessary support and access for personnel.
Modular engineering for Modular Fabricated Units:
The modular concept means all the necessary components, both process and ancillary equipment such as piping, instrumentation and electrical wiring, are designed to installed in a structural steel frame or mounted on a skid in a modular shop.
Everything is tested before delivery; the module is shipped via truck or barge and finally, installed on site. While there may be various levels of modularization, all modules are pre-fabricated to the maximum level of completion.
Plot Plan and Equipment Layouts.
Piping Isometrics & Plant GA Drawings.
Complete fabrication drawings for skid structure, piping spools, piping supports, MTO.
Overall skid layout to minimize site erection time and cost.
Layout optimization for proper access & operation with equipment/fittings engineering to suit skid mounting and operation.
With Digital disruption revolutionizing the
resources, data collation and integrity has become more important
now a day.
At Xytel India, a dedicated Team of E&I Personnel to provide the latest technology in process automation and control solutions for your Plant.
Our rich industry experience in process automation systems help us to provides a complete value added solution for your pilot plant.
We offer the complete process automation solutions form simple control loop to complex control systems as per customer and Pilot Plant Requirement.
Following are the activity carried out at various stage of Project Cycle,
Instrument Index, Instrument Datasheets, Single Line Diagrams, Cable Schedules, System Architecture, Control System.
DCS, PLC, SCADA, Operator Interface, Dedicated Controller.
Electrical / Control Panel Engineering
General Arrangements Drawings, Wiring Drawings, Terminals Arrangement, Loop Drawings
We have In-house facility for Panel Assembly and PLC/SCADA
Programing. We are Experienced with Allen Bradly, Siemens,
Honeywell, Schneider, Rockwell, GE Fanuc, Eurotherm (Controller)
PLC Programing. and for DCS we are experienced in Yokogawa (Centum
VP) and Emerson (Delta V).
There are many advantages to having this in house as compared to using outside. Time and Quality are the major advantages.
The project management team will collaborate from start to
completion ensuring the build is on time, within scope and complete
Once the plant design will meet the client needs, drawings are finalised and long-lead items are purchased without delay.
The build phase generally starts with the Structural Fabrication and our in-house team of qualified welders.
As the framework forms the skeleton of the build, constant consideration is given to the layout, with input from the design engineers throughout the build process.
The largest components are installed first, followed by others in order of decreasing size.
Vibration, lagging and future maintenance requirements are always considered when the components are located on the framework.
The components are then connected by pipework/tubingwork, with joints being compression fittings, flanges, welds or special fittings, depending on the Requirement.
Our mechanical technicians ensure pipe/tubingwork is laid out
efficiently and tidily.
During the mechanical build, the electrical racks are wired up and thoroughly checked. The final connection of instruments, heating jackets, pumps and other components are made, and the it is then ready to undergo commissioning and factory acceptance testing(FAT) in presence of Client.
All safety devices and pressure equipment that are not rated to the Test Pressure are removed from the equipment and connections blanked off. The pressure is then gradually increased, using inert gases/fluids such as nitrogen or water, with leaks being detected and eliminated.
The Test Pressure is maintained within the system for a minimum of 30 minutes and the equipment integrity is certified by inspectors.
The safety devices, which are inspected and verified separately, and pressure equipment are then replaced and the equipment taken up to the Working Pressure, where any further leaks are detected and eliminated. The final installation is then checked by one of our inspectors.
Once the wiring checks are complete, all fuses within the electrical panel are removed before mains power is connected to the electrical rack. In a systematic approach, fuses are replaced one-by-one while carrying out loop checking.
Safety alarms and executive actions are then tested in accordance with the trip schedule. Where process conditions cannot achieve the trip condition, the measurement is simulated using calibrated signal generators.
Control System Validation:
Once the mechanical and electrical commissioning is complete if applicable to the particular process, the control system is commissioned, again using inert gases/fluids such as nitrogen or water. Instrumentation and control valves are calibrated and control loops tuned.
Final commissioning starts with removing all inert gases/fluids and replacing them with process gases/fluids.
The plant is operated as per the user requirements and final calibrations to control loops and instruments are carried out, if required.
The equipment is then ready for handover and operator training.
We have a comprehensive equipment maintenance service that can take care of planned maintenance, modifications, equipment breakdowns, and equipment calibration on request.
If you have pilot plants or process rigs then We have expert process engineers that can design modifications to your equipment for improved performance or new tasks.
Apart from the main activity, we also undertake, as a pre-requisite for turnkey supply, a study to prepare pre-engineering document to convert bench / lab-scale data to into pilot / mini plant design when very little information about the process is available. This exercise is also useful for estimating the project cost enabling the client to arrive at an investment decision.
Xytel India offers specialized services to help clients revamp their existing pilot plant resources.
Xytel India also undertakes Annual Maintenance Contracts for Pilot/ Mini Plants. Each AMC has a designated service engineer in lead role and services will include visits at a mutually decided frequency, normal & preventive maintenance operations, guidance & training for proper operation & maintenance of pilot plants.
Automation technology is an integral part of chemical/Refinery plants since the beginning of industrial chemistry. The evolution of process automation has been driven by the specific requirements of process industry and by the innovation cycles of instrumentation technology and control theory.
Xytel India offers solutions to upgrade existing control systems to PLC based/ DCS based as the case may be.