Facility & Process Engineering

Wenck process engineer surveying a site as part of a Front End Engineering Design projectCoordinating effective management and engineering services for commercial needs is notoriously complicated, because no two engineering projects are the same. Whether you’re retrofitting an existing facility or planning to construct a new one, you’ll have to deal with a combination of unique, multidisciplinary design, planning, estimating, bidding, constructing, and compliance challenges. If you don’t account for these challenges effectively, your project could end up behind schedule, over budget, or, even worse: inefficient, ineffective, or dangerous.

Overcoming the unique engineering challenges facing your industry and project requires custom solutions. Merely consulting with experts isn’t enough; you’ll need to work with a process engineering company comprised of several multidisciplinary experts. The right management and engineering services team will A: get to know your project and its unique challenges, B: design their engineering solutions to overcome those challenges, and, most importantly, C: work together, combining their knowledge and expertise develop a single comprehensive project management plan to incorporates solutions, stay on schedule, and complete the work to your highest expectations. This is exactly how Wenck’s management and engineering services team approaches each of our jobs. If you need an expert process engineering company to help with your engineering project, Wenck is the right team for you.
 

Why Wenck?

Wenck’s management and engineering services team is a group of expert, multi-disciplined designers and engineers with decades of experience providing custom solutions for our client’s facility design and process engineering projects. We’ve partnered with clients of all sizes and industries, from start-ups to Fortune 500 companies, on all kinds of projects, from retrofits to greenfield construction.

When you work with Wenck on a process engineering or facility engineering services project, we serve as your “one-stop shop” consultants at all points during the project management process, from “napkin concept” through design, estimating, bidding, permitting, compliance, construction, and commissioning. We’ll use technology and documentation to find the fastest, most efficient, and most effective means of achieving your goals in order to make sure process development completes on time, within your budget, and to your highest expectations.

You should choose Wenck as your process engineering company because when you work with us, all you have to know is what you need to accomplish. We’ll figure out how to get you there.
 

What management and Engineering Services can Wenck Provide?

Wenck customizes our management and engineering services to meet your project’s needs. Whatever you need to complete a process engineering project on time–from mass and energy balancing to piping design, piping isometric drawings, to whole-facility 3D modeling–we can fit into the project management plan we will create for your project. We also provide specialty management and engineering services, including process safety management, energy auditing & conservation studies, waste to energy, water sustainability and arc flash hazard analysis/electrical system modeling, during development, to ensure that the completed process is safe, efficient, and effective as soon as it’s finished.

Wenck provides all of these services by consulting with you to see what your project goal is and then assigning the teams and resources necessary to achieve them. No two engineering projects are exactly the same, and so none of Wenck’s Facility & Process Engineering projects are the same, either. The services we perform for our clients and the capabilities we utilize to make them happen most frequently include:

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

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.

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.

How Do Wenck’s management and Engineering Services Work?

Wenck follows Front End Engineering Design (FEED) and Stage Gate engineering process approaches during all phases of a process engineering project. These structured methodologies ensure that our project and its implementation are economically feasible, environmentally sound, and fit within our client’s overall objectives. Wenck’s Facility & Process Engineering team starts by surveying your facility interviewing relevant team members. This initial consultation gives us the information we need to define project scope and goals, which, in turn, we can use to define the best feasible means of reaching those goals will be.

After determining feasibility, our experts define the specific deliverables necessary to provide required documentation in “stages” or “phases.” We define and implement a single stage at a time, starting with FEED. At the end of an initial FEED stage, we usually provide a +/-10% cost estimate. This estimate forms the basis for making the decision to move forward with a project where we’ll need substantially more funding. At the end of each subsequent stage, we review completed deliverables, make increasingly-accurate capital cost estimates based on project parameters such as piping design, and re-confirm project financials and goals. This allows your stakeholders to make informed, effective decisions about the next stage of work throughout the process.

Wenck’s staged approach ensures that our team keeps your goals and expectations top-of-mind throughout the process and enables us to provide the most efficient engineering costs and project timeline possible. The result is a process engineering project that fulfills your goals to your highest expectations as efficiently and effectively as possible, every time.
 

What are my Next Steps?

If you’re interested in getting Wenck’s help on your Facility & Process Engineering project, just get in touch with us online or call 763-292-3651. All you need is an idea of what you need to accomplish. We can help put together the rest. Wenck can usually set up our initial consultation in only 48 hours, so when you’re ready, we’re ready too. We look forward to making your goal a reality.
 

Wenck’s Facility & Process Engineering Services in Action

Canola oil processing facility Wenck performed a Facility & Process Engineering project on$180M CANOLA OIL PROCESSING FACILITY
Wenck acted as Lead Engineer for all engineering design services for a $180 million Canola Oil Processing Facility. The project consisted of design documents, drawings and isometrics, piping, valves, instruments, site development and design, and P&IDs and totaled over 39,000 hours. The end result client with a highly cost-effective and successful construction effort.

 

 

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

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