Neilsoft Limited

MODULAR PLANT DESIGN

Skid Design – Skid Mounted or Modular Process Plant is mainly decided based space optimisation and fast execution against regular upgradation requirement of Plant. As plant upgrade is complex, expensive and distressed work, which sometimes is avoided by Plant Manager, having the direct impact on improving Plant Productivity & Efficiency. Skid or Modular design comes as a solution to it. As these are Modular, fabricated at the shop which gives better quality and installation & Commissioning almost becomes very easy and hassle-free. We as engineering firm offers complete details engineering services for Skid or Modular design.

We have worked with world leaders of Process Industry working with Skid or Modular based design.

Some of the Skids or Modular Design Engineering carried out by us - Brine Evaporation Plant, HCL Synthesis Plant, Gas Dehydration system, Gas Compression – Vapour Recovery Unit, RO Booster Pump Skid, RO Module Skid, Compressor Packages, CIP (Clean In Place) – WTP/STP, Fuel Handling Unit, Oil & Gas Metering Skid.

Our offerings are as below:

• 3D modelling of complete skid including all discipline – Structural, Mechanical, Piping, & E&I
• E&I engineering including cable & cable tray, junction box etc.
• Extraction of 2D General Arrangement drawing for Piping, Structural and Electrical.
• Piping Isometric Extraction
• Lifting and Transportation arrangement design which includes Lifting lugs, Lifting arrangement details etc.
• Piping and Structural Analysis to optimise supporting arrangement and main structural frame members size.
• MTO/BOQ for Piping/Structural/E&I

DESIGN VALIDATION SERVICES

We are experts in carrying out various analysis such as Pipe Stress, Structural, and Electrical Network etc. We provide analysis in all Fields of Engineering as mentioned below:

Piping Flexibility/Stress Analysis (using Caesar II & Rohr 2)

Typical Deliverables provided as part of Analysis

• Critical Line list preparation based Design Guidelines
• Modelling for Flexibility/Stress Analysis
• Identification of optimised support location
• Design (Specification & Data Sheet) of various special components & support such as Variable & Fixed Spring
• Hanger, Expansion Joints, Rod Hangers etc.
• System Generated Report along with Stress Isometric showing all support Location
• Formatted Report – with consolidated details as below –
• Conclusion with qualification system safe
• Summary of Stress and Restraint
• Nozzle load Summary
• Summary of Live and Dead Load on Supports
• Drawings such as System generated 3D Plot and Isometric (with duly marked support location and type)

Structural Analysis – STAAD Pro, Nastran, SAP 2000, RISA 3D, ETABS

• Various Codes usages proficiencies – AISC, IS, ACI, AASHTO, BS, UBC & API, IBC 2012, ASCE 7-10
• Analysis and Design
• Load Carrying Capacity
• Minimum Retirement Thickness
• Special and Technological Structures
• Structural Stability – Non-linear Buckling
• Consideration of Various Loads such as Environmental Loads (Wind, Snow, Rain, Seismic etc.)
• Time History Analysis of Blast Resistant construction
• P Delta Analysis
• Finite Element Analysis
• Dynamic Analysis
• Analysis for Wind Tunnel Forces

Electrical Analysis – We are Specialised in below mentioned System Analysis using ETAP

We have proficiencies on working with Various Codes such as IEC, ISO and BS, IEEE, NFPA, NEC, ASTM, ANSI

• Load Flow & Short Circuit
• Harmonics
• Arc Flash
• We provided formatted report along with system generated report, some are as below for reference
• Final SLD after system analysis
• Summary Report Bus Load
• Summary Report Branch Loading
• Summary Report Branch Losses
• Alert Summary Report
• Summary Report of Total Generation (As Applicable), Loading & Demand

Mechanical Strength Calculation – We have strong Team to carry strength calculation using PV Elite/Compress

• We have proficiency in working with Various Codes such as ASME SEC VIII, Div I & II, TEMA, API 610, 650, ASRAE, NBC
• Analysis and Design
• Strength Calculation
• Modelling in PV Elite for analysisFlash
• Minimum Thickness requirement
• Consideration of Various Loads such as Environmental Loads (Wind, Snow, Rain, Seismic etc.)
• Reinforcement Pad Thickness calculation (i.e. Area Compensation calculation)
• Prepare GFC drawing based on analysis results
• Preparation Fabrication Drawing

Specialised Analysis –

• Finite Element Analysis - We have proficiency in carrying Static as well as Dynamic Analysis for application such as
• Any Type of structures/technological structures with heavy loads and vibration
• High-Temperature Vessels
• High-Temperature application Equipment such as Bag Filters, Conditioning towers, Silo & Cone Hooper
• Civil structures with heavy loads such as Cold Box Foundation, Compressor/Fans foundations,
• We carry FEA for following requirements –
• Stress analysis
• Durability analysis
• Fatigue analysis
• Vibration analysis
• Modal analysis
• Design optimization

Computational Fluid Dynamics – We are experts in HVAC engineering wherein we analyse

• Analysis and design of Air Flow system using Computational Tools
• Thermal Analysis for proper Air Flow distribution in closed room condition

MULTI-DISCIPLINARY PLANT ENGINEERING & DOCUMENTATION SERVICES:

Neilsoft provides multi-disciplined plant engineering services including Pre-bid engineering, Extended Basic Engineering Support, Plant Digitization, Detailed Engineering and Design, and Plant Documentation services for (plant) operations and control.
Today, plant owners, operators and other stakeholders face global competition, low-cost pressures, tighter construction norms and reduced time-to-market requirements. Moreover, the dramatic shifts in contracts(LSTK) and technology-driven design, procurement, and construction of projects to improve overall efficiency and reduce a cost(s) is a focus of every organization.

Intelligence, integration and modularity are the major future (plant) trends for cost reduction and faster plant engineering. Neilsoft with its multi-disciplinary (Process, Piping, Mechanical, Civil Structural and Electrical & Instrumentation) capabilities and BIM-enabled processes provide efficient plant design & equipment engineering services to owner-operator, EPC, EPCM, OEMs and technology providers. We help companies to realize their core strategic expectations from the plant project, improve their competitiveness, minimize project risks, and help optimize project completion times, hence reducing the overall project cost.

Whether you are expanding, upgrading, revamping/scaling-up existing pants, or establishing new plants, you can rely on Neilsoft’s cost-effective plant design services & solutions to help you achieve your business objectives.

We combine engineering and project management expertise & resources with strong domain experience to create value for our customers. Our team is equipped with a good understanding of various code's & standards, software platforms, and technologies to support clients in delivering projects across different locations in India, Middle East, Asia Pacific, USA, and Europe. We specialize in setting-up dedicated teams to support our customers continuously for their multi-project and multi-geography requirements.

Industries served to include chemicals, speciality chemicals, oil and gas, power generation, oil & gas, mining and minerals

COMPREHENSIVE PLANT PIPING DESIGN & ENGINEERING SERVICE OFFERINGS

Piping engineers must handle different codes, standards and specifications for Plant Piping and Layout creation. Moreover, error-free layout creation is important for getting accurate BOMs. They also spend a lot of time doing data consistency checks and creating multiple iterations. Having a good understanding of various load cases for piping flexibility analysis and pipe rack design is also critical when they do piping design. Neilsoft piping engineers understand these challenges and provide comprehensive services for Plant Piping from design (spec. creation, sizing calculations, catalogue creations, etc.), 3D modeling (using various platforms), IFC - Construction deliverables (GA drawings & Isometrics), Piping Analysis (flexibility analysis) and extracting intelligent reports (pipeline list, MTO’s, etc.). Our team of experts have experience across industries such as Oil & Gas, Chemicals & allied industries, Pharmaceutical, Food & Beverages and Utilities such as Water & Effluent Treatment, Renewal Energy and Power.

Piping Design Engineering

• Piping Study
• Preparation of design basis and standard drawings
• Preparation of piping material specifications (PMS)
• Pipe & Pump Sizing
• Preparation of equipment Datasheets
• Catalogue Creation
• Overall Plot Plan
• Design of Fire protection system
• 3D Modeling & Extraction
• Equipment Modelling and Layout
• Piping Modelling and Layout
• Piping Layout Extraction
• Pipe Rack and Secondary Support
• Equipment Layout Extraction
• Isometric Extraction
• Equipment and Pipe Line List
• MTO/BOQ
• Piping Flexibility Analysis
• Stress Analysis Model (CAESARII/ ROHR2)
• Analysis Formatted Report with Recommendation
• Stress Isometric
• Load List for Support Design
• Support Design
• Intelligent Reports
• Pipe and Pipe Fittings MTO/BOQ List
• Fasteners MTO/BOQ List
• Valve MTO/BOQ List
• Piping Support MTO/BOQ List
• Special Component MTO/BOQ list

CREATING AN ENTERPRISE-LEVEL PROCESS KNOWLEDGE REPOSITORY AND REUSABILITY
The key challenges faced by owner-operator and consultants are to create accurate specifications, the creation of multiple options (for process design), selection of optimum Equipment, accurate estimation, re-work, reusability of drawings/specs, design review process and accuracy of reports. Engineers spend a lot of time in creating drawings and generating CAD outputs instead of focusing on their core (engineering/design) activities. Neilsoft assists an organization in creating such CAD outputs using intelligent tools. It helps companies to create a knowledge repository and create (process) design options based on the inputs from the customers. We help in sizing of utilities based on preliminary inputs along with using various latest tools. We deliver the intelligent outputs (deliverables) and assist its clients in the management of the change across the project life-cycle. Whether it is converting legacy data into digital & intelligent formats or updating existing assets as per operating condition (for e.g. uniformity in Tagging standards), or assistance in creating design options for design review; Neilsoft work as an extended arm of our client’s engineering team and provides flexibility and scalability for faster turnaround of designs.

Key Service Offerings:

• Intelligent (spec-driven) Piping and Instrument Diagrams based on preliminary PFDs
• Heat and Mass Balance Diagrams
• Water Balance Diagrams
• Hydraulic Analysis – Pipe Sizing & Pressure Drop Calculation
• Line List & Equipment List.
• Piping Design Basis.
• Piping Material Specifications.
• Mechanical Static Strength Calculations & Equipment Sizing
• Electrical Equipment Sizing/Optimization using ETAP
• Civil & Structural Design Optimisation
• Indicative Plot Plan & General Arrangements.
• Technical Specifications & Datasheets of Various Equipment
• Legacy data conversion (old P&IDs to smart P&IDs)

EI&C ENGINEERING SERVICE OFFERINGS
In today’s changing scenario of Automation and Control, every aspect of Plant engineering is becoming smart and intelligent starting from SMART MCC/PCC to SMART Instruments with all control & monitoring being done remotely. We have always kept our self-upgraded to present requirement and suggested client depending upon Plant process complexity requirement whether to go with the SMART System or conventional system. This is today biggest challenge with every customer – How far they should go being SMART & Intelligent. We are expert in optimising and bringing balance in choice. We are proficient in Network Analysis and optimisation of Equipment Sizing which directly has an impact on the cost of equipment – helps reducing overall CAPEX. We have successfully completed projects using various codes such as IEC, ISO and BS, IEEE, NFPA, NEC, ASTM, ANSI. We have successfully executed and delivered optimised Plant in sectors such as Oil & Gas, Chemicals, Energy (Renewable & Non-Renewable), F&B, Petro-Chemicals etc.

Our Offerings:

• Electrical Power distribution configuration for HV, MV & LV system (132kV, 66kV, 33kV, 11kV, 6.6kV, 3.3kV, 415V etc.)
• ETAP studies i.e. short circuit & load Flow studies
• Preliminary Field Layout Single line diagram
• System design & electrical equipment's sizing
• Power/control cable sizing & schedule
• Substation equipment layouts & sections
• Cable trench/cable tray layouts
• Earthing and lightning protection layout
• Lighting and small power layouts
• Standard installation details
• Tender documents, bill of quantities & cost estimates
• Instrument Index/IO list
• Sizing calculations for flow elements and control valves
• Control room layouts
• Instrument location & junction box layout
• Instrument Hook-up drawings
• Instrument Loop drawings
• PLC & SCADA/DCS system (Any Type)
• System Configuration
• PLC Panel -GA & schematic drawing
• Hardware & Software systems,
• Networking system
• HMI & tagging philosophy