Facility & Process Engineering

PROCESS SOLUTIONS TAILORED TO YOUR FACILITY

Each project you undertake is unique, which is why you need professionals with in-depth experience to fully understand your objectives and provide customized, expertly crafted solutions to meet your needs. Our multi-discipline engineers & designers have decades of experience providing solutions for our clients. We have partnered with startups to Fortune 500 companies and facilities ranging from retro-fits to green fields. From mass and energy balances and smart P&IDs to 3D modeling and piping design, your process will be fully defined from the start. We can also provide specialty process services such as process safety management, energy auditing & conservation studies, waste to energy, water sustainability and arc flash hazard analysis / electrical system modeling to give you the confidence you need in a completely designed system that will be safe, efficient and fully functional.

SERVICES AND CAPABILITIES
Front-End Engineering Design & Estimating
Food / Sanitary Facility Design
Oilseed Facility Design
Bioprocesses & Renewables
Process Safety Management
3D Laser Scanning
Virtual Design (Virtual Reality & Augmented Reality)
Front-End Engineering Design & Estimating

Wenck offers Feasibility, Front End Planning, FEED, and Stage Gate development of projects and has deep experience working with clients to scale up designs for new technology in the industrial and bio process spaces.

The Stage Gate process provides companies a structured methodology to ensure a project is economically feasible and fits with a company’s overall business and stakeholder objectives.  The process allows management of risks including that the project is safe, environmentally sound, and is designed appropriately to protect stakeholder interests.

From feasibility, specific deliverables are defined that provide the documentation required at the end of each ‘stage’ or ‘phase’.  At the end of each stage, these deliverables along with capital cost estimates of increasing accuracy are reviewed to confirm project financials and goals to allow stakeholders to make effective business decisions to proceed to the next stage of work.  At the end of the FEED stage typically a +/-10% cost estimate is provided which is the basis to make the final decision to move ahead with a project where substantially more funds are committed to purchase equipment, build foundations and start to install structure, piping, instrumentation. This staged approach enhances alignment of stakeholder’s expectations as the project is developed and reduces risks considerably while providing efficient engineering costs and shortened project schedules.

Food / Sanitary Facility Design

We have decades of knowledge and experience in food and dairy processing. Our former plant engineers and staff with OEM equipment manufacturer backgrounds bring a unique perspective, ensuring we understand the complexities of producing ready to eat food products. Wenck’s multi-discipline team provides complete process design, from incoming raw materials to finished product:

  • Grinding and Milling
  • Material transfer
  • CIP / COP
  • Ingredient Delivery and batching
  • Pneumatic Conveying and Material Handling
  • Packaging and Palletizing
  • Food Grade and USDA 3A Dairy compliance
  • Demountable equipment design for tool-less in field cleaning
  • Hygienic HVAC Design, filtration, pressurization, Air Handling Unit internals for clean-up
  • Culinary Boiler steam and Hot Water clean-up systems
  • Detailed piping/insulation/jacketing design for food plants
  • Industrial Refrigeration Design
  • Food grade compressed air/oil-less
  • Dust control
Oilseed Facility Design

From innovative plant design and layout to process engineering and environmental services, Wenck’s experienced engineers & designers can assist with your new facility or next expansion. From grain receiving, cleaning, crushing, oil extraction, meal processing, refining/bleaching/deodorizing, meal/oil storage and loadout, our understanding of oilseed processing and relationships with multiple specialty equipment suppliers and construction contractors ensures efficient design and proper selection of equipment:

  • Preliminary design to develop conceptual designs and information required for project feasibility and funding
  • Detailed design including specifications and documentation required for construction
  • Innovative facility design utilizing latest technologies including 3D laser scanning, 3D modeling and incorporation of models into Virtual Reality
  • Assistance with environmental permitting
  • Site layout and development
  • Dust control and aspiration system design
  • Utility system design for steam/condensate, compressed air, process water, and cooling water
  • Wastewater re-use and energy conservation system design
Bioprocesses & Renewables

We  have the diverse knowledge and in-depth experience required to implement our client’s often novel ideas, scaleups needs, and processes for a wide range of technologies such as fermentation, anaerobic digestion, biomass deconstruction, and catalytic upgrading. Throughout the project duration, our clients are guided with solutions to create successful outcomes. We prioritize safety in project design, particularly when handling hazardous materials, inherently resulting in safer design solutions. From coordination with equipment to specialty system suppliers, we provide design and selection for all the systems and infrastructure required to operate a facility.

Process Safety Management

Wenck provides Process Safety Management (PSM) and Risk Management Plan (RMP) compliance related services. The PSM and RMP programs are administered by OSHA (29 CFR 1910.119) and the EPA (40 CFR 68) for management of hazardous chemicals.  With primary focus on Ammonia Refrigeration, we also perform PSM related work on facilities with flammables, chlorine, and other chemicals.  Wenck is familiar with current codes and standards as well as RAGAGEP for ammonia refrigeration systems and flammables containing processes.

Compliance Services:

  • Full initial PSM program development to fulfill the PSM & RMP standards.
  • Assistance with RMP initiation for new facilities as a designated ‘preparer’.
  • Three-Year Compliance Audits conforming with 29 CFR 1910.119 (o) and 40 CFR 68.79.
  • Process Hazard Analysis for new facilities or a five-year revalidation conforming with 29 CFR 1910.119 (e) and 40 CFR 68.67.
  • Project Hazard Review to fulfill Management of Change requirements to consider impact of change on safety and health as a project centered PHA. (29 CFR 1910.119 (l)(2)(ii) and 40 CFR 68.75 (b)(2)).
  • Third-Party Compliance Audit when required for RMP covered facilities to fulfill requirements in 40 CFR 68.58, 68.79, 68.80 (implementation by March 15, 2021 per EPA).

Benefits of using an independent third party for PSM and RMP compliance: 

While third-party involvement in a facility PSM/RMP program is not required by the standard (yet, as noted above) it can still provide beneficial results to your program.  A third-party compliance auditor will not be biased to the quality of an existing program or fearful of repercussions from findings of non-compliance.  They also bring ‘fresh eyes’ to a facilities’ PSM program and can provide insight to help streamline a PSM program or PHA facilitation session.  Wenck has provided PSM services to numerous facilities and can help manage your PSM program properly.

3D Laser Scanning

3D scanning is a safe, alternative way to collect large amounts of data in a fraction of the time compared to manual data collection. Wenck’s state-of-the-art Leica RTC360 3D laser scanning system operated by experienced technicians and designers can measure up to two million points per second with an accuracy of 2.9 mm at 20 m. The automated, real time field registration creates colored, 3D point clouds and HDR images in an efficient manner. With gathered data, Wenck helps our clients collaborate and complete complex projects in a safe, timely, and cost-effective manner. Laser scanning has also been shown to reduce engineering costs by 10%.

Deliverables include:
• 3D CAD models created from the scan data
• Raw Point Cloud Data if the client desires to create their own 3D models
• High definition photorealistic images utilizing TruView which allows everyone on
your project team to view the project site from anywhere, anytime
• Wenck can also provide complete design drawings from the information generated by the scan and 3D models
• Integration into VR and AR models

Potential uses include:
• Existing facility upgrades and expansions
• Reverse Engineering (3D model creation of existing sites and structures)
• Clash detection
• Stock pile and other features volume measurements
• Forensic data gathering and documentation
• As built construction verification
• Pre and Post Construction scanning to  capture locations of conduits, rebar, etc. in  walls and slabs
• Scanning existing conditions to provide  detailed specifications for the removal of  asbestos and other regulated materials

Virtual Design (Virtual Reality & Augmented Reality)

Virtual Reality is a 3D computer generated environment that enables individuals or teams to become immersed in this environment allowing them to manipulate and investigate features inside the model.

The use of Virtual Reality is relatively new for engineering and industrial clients, but the potential uses are endless. With Virtual Reality, clients can have their stakeholders walk through a three-dimensional model of a new or upgraded facility to see what it will look like before it is built.

  • Constructability/design reviews
    • The VR model allows all team members to understand the complexities of the design, allowing better planning for constructability and logistics.
    • Stakeholders can walk through the facility and familiarize themselves with the layout and locations of critical items such as equipment, valves, and instruments prior to the start-up of the facility, reducing the amount of time it takes for them to get up to speed.
  • Operator training
    • Having the virtual reality model available before a new facility start-up allows plant operators to familiarize themselves with the layout and prepare themselves for the day-to-day activities that will be required to operate the facility.
    • It can also be used for competency training by observing how an operator reacts to different situations.
    • Operators can learn the dangers associated with the new facility and acquire the safety knowledge required and prepare drills to ensure safe operation of the facility.
    • Queries of objects provides people with information of that object such as drawings, maintenance records or operating conditions.
  • Remote collaboration is possible by allowing people in multiple locations around the world to immerse themselves real time in the virtual model, streamlining the design process.

Wenck has the expertise to develop a VR model of existing or new facilities and provide a Virtual Reality system to work within, including set up and training to get the most out of the technology.

Augmented Reality is the next step in this immersive environment and allows a person to not only immerse themselves into a virtual world but allows them to overlay digital images and information onto the physical world around them. This can be accomplished using a smartphone or tablet.

We welcome the opportunity to learn more about your organization's facility & process engineering needs.

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