From feasibility assessments to advanced safety and risk management, we deliver precise, industry-leading services to optimize your project outcomes. Explore tailored engineering solutions for your next venture.

Specialized Studies includes the following :

Stress Analysis

What is Stress Analysis

Stress analysis is used to evaluate the effects of pressure, static and dynamic loads on the piping.

Comprehensive Modeling of Piping Systems - We create detailed models of piping systems and connected process equipment, ensuring accurate simulation for industrial applications.
Application of Static and Dynamic Loads - We conduct thorough experiments by applying both static and dynamic loads to assess the performance and resilience of piping systems.
Compliance with Industry Standards - Our stress analysis models are meticulously validated to comply with the latest industry standards, guaranteeing optimal safety and reliability.
Commitment to Safety and Reliability - Elixir Engineering is dedicated to maintaining the highest safety and reliability in industrial processes, as demonstrated by our latest case study in stress analysis.
Recent Case Study in Pipe Stress Analysis - The latest stress analysis of pipes highlights Elixir Engineering's expertise and commitment to optimizing the performance of piping systems for diverse industrial operations.

Want to learn Stress Analysis in Practice?

Explore our Case Studies to see how Stress Analysis have helped companies evaluate the effects of pressure, static and dynamic loads on the piping

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Structural Analysis

What is Structural Analysis?
Structural Analysis is the evaluation of the impact of external forces, such as loads and pressures, on tangible objects

Purpose of Structural Analysis
This process helps engineers predict how different structures will behave under various load conditions, ensuring safety and stability in design.
Key Benefits of Structural Analysis
Structural Analysis aids in optimizing the size and shape of structural components, ensuring that they can handle anticipated loads effectively and efficiently.
Material Selection through Structural Analysis
This analysis provides insights into the best materials to use, enhancing both the durability and sustainability of the structures.
Critical in Modern Construction and Design
With Structural Analysis, engineers ensure compliance with safety standards and regulations, minimizing risks associated with structural failures.
Foundation for Cost-Effective Engineering
By understanding how structures respond to forces, engineers can reduce unnecessary material use, leading to cost savings without compromising safety.

Want to learn Structural Analysis in Practice?

Explore our Case Studies to see how Structural Analysis is performed

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Computation Fluid Dynamics

What is Computational Fluid Dynamics (CFD)?

Computational Fluid Dynamics (CFD) is the use of numerical analysis and algorithms to solve and analyze fluid flow, heat transfer, and related phenomena. Utilises advanced computational models to simulate the behavior of fluids (liquids and gases) under different conditions.

Applications of CFD: Commonly used in engineering to optimize design, enhance performance, and predict operational outcomes in industries like aerospace, automotive, chemical processing, and energy.

Key Features and Benefits of Our CFD Services:

Expertise in Meshing and Quality: Our CFD team excels at ensuring precise meshing techniques, vital for accurate simulation results and optimal performance.
Advanced Fluid Simulation Strategies: We employ a range of fluid simulation strategies and techniques to provide reliable and efficient solutions.
Comprehensive Fluid Dynamics Understanding: Our team has deep knowledge of fluid physics, enabling accurate predictions and optimized designs.
Versatile Engineering Applications: We handle various engineering activities such as performance calculations, design validation, and evaluation of operating conditions.
Efficient Solutions: Delivering optimum solutions with minimised downtime, enhancing overall system efficiency and reliability.

Vibration Analysis

What is Vibration Analysis

Vibration analysis is a critical method that monitors the levels and patterns of vibration signals in machinery, components, or structures.

Identify Equipment Issues: Detect misalignment, bearing defects, imbalance, and mechanical looseness in machinery.
Assess Shaft Integrity: Analyze bent shafts and gear drive faults to ensure optimal performance.
Evaluate Resonance: Measure resonance to prevent potential equipment failures and downtime.
Root Cause Analysis: Use vibration data to evaluate the root cause of anomalies for effective troubleshooting.
Preventive Maintenance: Implement insights from vibration analysis for proactive maintenance and reduced operational costs.
Enhanced Equipment Lifespan: Improve the longevity of machinery by addressing vibration-related issues early.
Data-Driven Decisions: Leverage comprehensive analysis reports to inform strategic maintenance planning.

Flare Radiation & Dispersion Study

What is a Flare Radiation and Dispersion Study?

A Flare Radiation and Dispersion Study analyses the impact of flare stacks used in industries to burn off combustible gases. It evaluates the thermal radiation and dispersion of gases to ensure safe and environmentally compliant operations.

Controlled Flaring Process: Understand the importance of controlled flaring in natural gas production and its role in maintaining safety during operational upsets.
Thermal Radiation Assessment: Evaluate the extent of thermal radiation emitted during flaring, ensuring safety for personnel and surrounding environments.
Stack Height Estimation: Determine optimal stack height to effectively disperse emissions and minimize impact on nearby structures and communities.
Emergency Preparedness: Provide strategies for safely disposing of gas during power outages, equipment failures, and other emergencies through flaring or ventilation.
Comprehensive Study Approach: Utilize advanced modeling techniques and simulations to analyze flare radiation and dispersion patterns.
Regulatory Compliance: Ensure adherence to environmental regulations and standards related to gas flaring and emissions.
Risk Mitigation: Identify potential risks associated with flaring operations and recommend best practices for mitigation.
Operational Efficiency: Enhance operational protocols to balance safety, efficiency, and environmental impact during gas flaring activities.

Surge Analysis

What is Surge Analysis

Surge analysis involves examining pressure changes within a piping system triggered by various factors. These changes can result from the opening or closing of a valve, or more complex scenarios such as the activation or deactivation of one or multiple pumps, whether planned or unexpected.

Importance of Surge Analysis: Essential for evaluating surge impacts in hydraulic systems to prevent leaks and failures.
Impact of Surge Pressure: Sudden pressure changes can lead to:
- Pipeline damage
- Equipment failure
- Bursting of pipelines
Comprehensive Assessment: Conduct thorough surge analysis to estimate system performance and identify surge causes.
Mitigation Strategies: Provide tailored recommendations for surge mitigation to enhance system reliability.
Expertise at Your Service: Our team of experienced hydraulic engineers utilizes advanced software for precise analysis.
Client-Centric Approach: Committed to fulfilling client requirements to the highest industry standards.
Enhanced System Safety: Ensure operational safety and efficiency through effective surge management.

Finite Element Analysis (FEA)

What Is FEA?

A sophisticated, computerized method for predicting how products and engineering components react to real-world forces, such as vibration, heat, and fluid flow

Key Benefits:
- Predictive Analysis: Assess potential product failures, collapses, and wear before physical testing.
- Cost-Effective: Reduces the need for extensive experimental testing, saving time and resources.
- Design Optimization: Enhances product design by identifying weaknesses early in the development process.
Applications Across Disciplines:
Used in various engineering fields, including mechanical, civil, aerospace, and automotive engineering.
Methodology:
Breaks down complex structures or components into smaller, manageable finite elements to simplify the analysis process.
Alternative Testing Method:
Serves as a viable alternative to traditional experimental testing, aligning with many industry standards.
Real-World Impact:
Helps engineers design safer, more reliable products while minimizing risks and enhancing performance.

Advantages Of FEA In Pressure Vessel and Piping

Improved Safety Standards: Enhances the safety of designs by providing accurate assessments and insights that align with practical engineering requirements.
Enhanced Structural Strength Estimation: FEA provides accurate assessment of structural integrity, allowing for better prediction of strength and behavior under various loading conditions.
Comprehensive Modeling and Simulation: It facilitates detailed modeling of complex geometries and loading scenarios that beam element software may not handle effectively.
Design Optimization: FEA aids in optimizing designs by identifying stress concentrations and enabling modifications that enhance performance while minimizing material use.
Accurate Stress Analysis: Unlike traditional beam theory, FEA accounts for the nuances in stress distribution, especially in larger diameter pipes and intersections.
Mitigation of Limitations in Standards: Addresses inaccuracies found in piping codes (like B31) regarding stress intensification factors (SIFs) and flexibilities at intersections, leading to safer designs.
Identification of Hidden Issues: Capable of uncovering potential problems that beam element software may overlook, reducing the risk of unsafe designs.
Cost Efficiency: Reduces unnecessary costs by eliminating the need for excessive fixes based on inaccurate stress or loading predictions from conventional methods.
Practical Solutions for Real-World Challenges: FEA software is specifically developed to tackle engineering challenges that arise in piping and pressure vessel design, providing more reliable solutions.

Buckling & Plasticity

In piping and pressure vessel geometries that have large D/t ratios and/or external pressure, buckling is a cause for concern. Finite Element Analysis of Pressure Vessels helps analyze buckling with traditional bifurcation and elastic-plastic collapse study.

Thermal Solutions

Through-the-wall thermal gradients often result in significant stresses. FEA Software can analyze steady state transient thermal stresses.

When Is It Good To Conduct Piping FEA?

To check for any nozzle loads (WRC 107/297 are not comprehensive and often inaccurate).
To examine large branch/shell intersections (d/D>0.50)
For piping or pressure vessels with D/t rations more than 100.
For flange analysis – to calculate the accurate operating bolt load
To estimate SIFs and flexibilities accurately for your piping analysis.
For external loads on saddle supported vessels.

Critical Use Cases For Finite Element Analysis:

For compliance with code requirements for buckling in complex systems.
To calculate realistic stresses for nozzles with external loads.
When your piping systems exceeds D/t>100. Piping code rules don’t cover larger D/t systems.
Conducting accurate fatigue analysis for nozzles or attachments.
If the design isn’t governed codes and standards – large angle cones, rectangular openings, etc.

De-bottlenecking Studies - Process Optimization

Strategic Decision-Making: Enhance capacity utilization and mitigate uncertainties through targeted process optimization.
Efficient Upgrade Planning: Adapt to changing circumstances by implementing effective upgrade plans, ensuring seamless transitions.
Quality Enhancement: Boost program quality while maximizing return on investment in process modifications.
Advanced Tools: Leverage cutting-edge technologies and skilled manpower to deliver optimal quality in de-bottlenecking services.
Cost-Effective Solutions: Identify and capitalize on hidden opportunities in existing oil and gas plants to improve production efficiency at a fraction of the cost of new facilities.
Quick and Safe Execution: Implement debottlenecking efforts swiftly and safely, minimizing operational disruptions while enhancing production capacities.
Boost Financial Health: Increase plant production and revenue without the need for significant capital investment in new projects or expansions.
Hidden Opportunities: Discover and utilize inconspicuous enhancements in existing plants to realize substantial financial benefits with minimal effort.
Low-Hanging Fruit: Focus on easily accessible opportunities that can significantly improve plant efficiency and profitability.
Real-Life Case Studies: Learn valuable insights and guidelines for successful debottlenecking operations based on proven industry examples.

Debottlenecking of existing oil-gas plants brings significant economic benefits

Key Benefits

Low labour requirement making it economical
Exceptional result
Durable solution
Supports modernization
Timely execution
Quality assurance

Applications

Chemical plants
Petrochemical industry
Oil Refineries
Gas Compression

Where and how to find hidden opportunities. Most plants have sweet spots, or “opportunity packs,” from which such initiatives can be developed. However, constraints or bottlenecks may hold back their productive exploitation. Only experienced eyes can recognize and weigh the worth of these opportunities against the operational challenges present in a brownfield plant environment.

Four such prospective opportunity packs include:

Feed composition or product quality no longer match the original design and purpose of the plant. If proposed changes are favorable, they often signal a major scope for enhancement, with minimum required physical changes to the plant.
As a standard practice, a 10%–20% over-design margin is provided in most process plants during initial design. This margin may still be entirely, or partly, available for utilization if some minor to moderate changes are made to existing processes and equipment.
If some existing processes and equipment are found to be inefficient, costly and/or outmoded, their upgrade or replacement may directly increase capacity and efficiency, and reduce OPEX.
A small number of underperforming, high-maintenance equipment is often found to undermine an entire plant’s productivity. This equipment should be considered for upgrading or replacement to increase the plant’s reliability, availability and maintainability (RAM).

These opportunities can be realized through troubleshooting and debottlenecking. Such projects typically start with a test run that pushes the plant to its limits, with an occasional adjustment of equipment and operating parameters, based on the judgement of operating personnel. These steps should be followed by a comprehensive feasibility report that includes a cost-benefit analysis, which will help develop a work plan for the entire program.

An exemplary case history. A successful debottlenecking project in a gas treatment and NGL plant resulted in a substantial capacity increase of 33%, or one-third of the plant’s original nameplate capacity of 450 MMscfd. At this plant, a number of crippling process and equipment problems were redressed to push the plant’s onstream factor from a range of 90%–94% to as high as 96%–97%, bringing a significant financial benefit.

The execution strategies applied demonstrate the importance of good planning and the depth of technical involvement required to carry out a successful debottlenecking project at a running plant. The details of this study are shared to guide and assist plant personnel wishing to undertake debottlenecking projects in the future. Although the referenced plant is a gas plant, the strategies and techniques used can be applied to debottlenecking efforts for any process plant, be it an oil processing or chemical production plant.

Stage 1. Typically, opportunities in this pack became visible right after a close review and analysis of data and past records. In the referenced plant, a major difference was observed in the feed stream from what was considered in the design; H2S was decreased by 40%–50% and condensate was reduced by 35%–40%.

Sales/product gas quality was also found to be over-specified in the design, compared to what customers required and what was outlined in the supply contract. Approximately 60%–90% of sales gas was consumed by local power and desalination plants, which could accept up to 50-ppm H2S, with no stated limit on CO2, provided that the minimum heating value requirement of 910 Btu/scf was met.

The gas injection compressors for enhanced oil recovery (EOR) were another main consumer. These compressors could accept H2S of similar quality but required no limit on CO2, as long as the gas was dry, as specified

Since the deviations were on the lower side, a large opportunity was foreseen for this plant. A 10% increase in capacity appeared to be possible by changing some operating parameters and process conditions. Hardly any physical changes in plant and equipment, or any capital investment, was envisaged. These items were chosen for Stage 1 since they could be completed quickly, and the economic returns could begin earlier. Due to a reduction in acid gas content (H2S + CO2) in the feed gas and higher H2S allowance in the sales gas, minor changes to processes and operations were adequate to achieve the target:

The H₂S specification in the sales gas was raised to 20 ppm from the original 4 ppm. Accordingly, the diethanolamine (DEA) circulation rate was reduced by 30% to match the changed conditions. This change also reduced the duty of the circulation pumps, aerial coolers and the regenerator section, resulting in significant steam and power savings.
The steam controller and valve were tuned and recalibrated for smooth operations matching the reduced steamflow rate to the regenerator reboilers.
No change was required to the downstream units [e.g., the dryer, chillers, turboexpander, NGL recovery and fracing units, condensate stabilization unit, sulfur recovery unit (SRU), etc.] which were found to have adequate margins from their design. Condensate, NGL and sulfur content in the feed stream were lower than in the design.

Stage 2. The objective of this pack of items was to capture most of the 10%–20% margin added during the plant’s design stage. The performance test carried out following the completion of Stage 1 reconfirmed the presence of these margins. The new target was set for a 10% increase over Stage 1 capacity by deciphering major bottlenecks:
- The amine absorber tower foamed severely at a high flowrate, resulting in high amine loss, off-spec product and high flaring. The problem originated from aerosol/mist formation at high velocity in the well flowlines that escaped the separators and filters and reached the tower. The issue was solved by reducing the separator high-liquid level (HLL) and replacing the demister pads and filter elements with high-efficiency pads and elements with improved design.
- Continuous dosing of a small amount of antifoam agent was also implemented, alongside the existing shock-dosing system, to combat the high-foaming situation. The frequency of laboratory foam tests (i.e., height and breakdown time) for amine samples was also increased to acquire advance warning of foaming tendency.

Due to the increase in moisture load to the dryer at higher feed rates, dry gas specification became difficult to meet. The load was externally reduced to the pre-debottlenecking level by decreasing the dryer inlet temperature from a range of 30°C–32°C to 28°C by adjusting the flowrate of cold streams to the upstream cross-heat exchangers.
Glycol carryover from the triethylene glycol (TEG) contactor also increased at high velocity. The tray downcomers were found to be limiting, causing poor vapor-liquid separation and high carryover. All existing trays were replaced by new trays with more bubble caps and wider downcomers. The demister pad was also replaced with a thicker and more efficient type to reduce liquid reentrainment inside the pad.
High erosion, and the recurrent failure of the high-pressure absorber level control valve (a tiger-tooth-type valve), made absorber operation difficult. The erosion often required unplanned shutdown of the absorber for repair or replacement. The problem resulted from severe cavitation inside the valve due to large pressure drop (> 50 bar). The problem was finally solved by replacing the existing valve with a Q-ball-type valve and by introducing a choke tube upstream.
The turboexpander-recompressor (TE-RC) set suffered a design snag from the beginning that prevented the attainment of rated capacity. The Joule-Thomson valve that operated in parallel with the expander took the balance load, after minor process adjustments. Although NGL recovery dropped marginally, the hydrocarbon dewpoint of the sales gas was still met. The TE-RC was later refurbished in Stage 4 by changing the rotor.

Stage 3. The enhancement target for this opportunity pack was set at 10% over the Stage 2 target. The test run performed after Stage 2 confirmed that most of the major equipment, such as the absorber, regenerator, reboilers, coolers, glycol contactor tower, chilling unit, NGL unit, SRU, major pumps and heat exchangers, contained the potential to meet the expected target (i.e., from the original nameplate capacity of 450 MMscfd to 600 MMscfd).

However, some equipment, process systems and piping required refurbishment and upgrading to ensure efficient, safe and sustained operation, which required additional investment. Based on a “remaining life” assessment conducted at that point, as well as a lifecycle cost analysis of benefits and costs, proposed changes were found to be very attractive. Process changes included:

DEA was replaced by generic methyl diethanolamine (MDEA) due to the latter’s ability to remove H₂S selectively over CO₂. The amine circulation rate could be reduced since less CO₂ was to be removed by amine, and the sales gas specification was relaxed from 4 ppm to 20 ppm. As a result, steam and power requirements dropped by more than 30%. Sales gas yield per unit of feed gas flow increased due to the higher amount of CO₂ slipping into the sales gas. This scenario allowed higher gas flow to the gas injection system for EOR. Only the steam control loop and valve needed minor modifications to operate efficiently at a lower steam flowrate.
H₂S in the acid gas stream (i.e., the feed to the SRU) increased from 30% to approximately 45%, due to lower CO₂ coabsorption by MDEA. This led to increases in capacity and performance of the SRU. By default, the problem of frequent flame failure in the sulfur burner due to the low H₂S concentration in the acid gas was also eliminated.
Due to lower CO₂ removal by MDEA, the acid gas volume entering the SRU remained nearly unchanged, despite an increase in plant feed of 33%. Total sulfur (H₂S) load to the SRU also remained nearly unchanged, as the H₂S in the feed gas was lower than that considered in the design. Hence, no tangible impact was recorded on the SRU sulfur burner, catalytic reactors, waste heat boiler condenser, incinerator, etc. Only a few minor changes and adjustments were required for the SRU.

Equipment and hardware changes included:

The 21 trays in the amine absorber were replaced by stainless steel (SS) random metallic tower packing (RMTP) of 50-mm diameter, which raised absorber capacity by 40%. Post-weld heat treatment, hydrostatic tests, recertification, etc. were avoided by using redundant tray supports, hangers, rings and other equipment already present in the tower.
In the glycol contactor, all seven trays were replaced by SS structured packing. Glycol flowrate was increased by 15%–20% by adjusting the speed and stroke of the reciprocating glycol feed pumps. Stripping gas flow to the regenerator bottom drum was also increased marginally.

Stage 4. The remaining problems that eroded the plant’s onstream factor to 90%–94% were tackled in this stage. At least 96%–97% was expected to be achievable, since the plant underwent no annual complete shutdown. Instead, it underwent modular shutdowns for inspection and planned maintenance. Some of the problems solved in this stage may be typical of other process plants:
1. Expander-recompressor lube oil viscosity continuously dropped during operation (normal: 30 cst at 40°C) due to the absorption of hydrocarbons (C₄+) from heavy seal gas, tapped from the inlet side of the expander. The off-skid oil filtration-conditioning unit could not resolve the problem. By shifting the seal gas tapping from the expander’s inlet side to the outlet of the recompressor the location changed from (A) to (B), and the issue was resolved.
2. The inlet guide vane of the TE-RC often jammed during operation due to hydrate formation on the inlet guide vanes. An investigation confirmed that, occasionally, moisture breakthrough occurred from the upstream dryer, which the faulty online moisture analyzer failed to detect. The moisture analyzer was replaced with a more efficient model, and periodic calibration was implemented to ensure that both dryer and analyzer performed satisfactorily. Also, the continuous injection of small doses of methanol at the inlet of the chillers and the expander was resumed, eventually eliminating the problem.
3. Frequent regenerator-reboiler tube cutting at the baffle plates was a major problem that could not be solved, even after attempting several alternate designs, such as rod-baffle design, change of tube pitch and arrangement, and change in number of plates. The problem was found to originate from unnoticeable tube thinning due to corrosion from DEA. This corrosion occurred in the pre-MDEA period, when residual H₂S in lean amine and steam temperature (superheat) were higher than the ideal values.

After the transition to MDEA, stringent control of residual H₂S, and reintroduction of the steam desuper heater, the corrosion rate dropped to less than one-fifth of the previous level, and the tube-cutting problem disappeared. Use of SS tubes could have been another viable solution, but this was not considered since the feed gas often contained high chlorides from the wells. At high reboiler temperatures, these chlorides are highly detrimental to SS. Also, SS was determined to be 2.5–3 times costlier than carbon steel (CS).

The debottlenecked plant has been running for more than 20 yr at 133% (150 MMscfd over its nameplate capacity), at a much higher efficiency and plant availability, and without any major incidents, lost-time injuries or extended shutdowns.

HSE issues in debottlenecking. Any debottlenecking operation invariably results in some amount of departure from the plant’s original design premises and operating envelope. For this reason, the original safety procedures, protection philosophy, test certificates, etc., will require a fresh review.

The following health, safety and environmental (HSE) initiatives brought an impeccable safety record to the referenced project:

Hazard identification and hazardous operations reviews are conducted at various stages, including reviews of pressure and temperature diagrams, pressure and protection systems, material safety data sheets, emergency flare and disposal systems, etc., at the beginning and end of the debottlenecking project.
Work inside the live plant area was minimized through careful planning; unavoidable activities were only performed after proper risk assessment was conducted, and a mitigation plan and precautionary measures were put into place. Permit-to-work protocol was strictly followed for all work carried out inside the live plant.
The health of all equipment subjected to high pressure, high temperature and/or H₂S was assessed by using visual inspection, ultrasonic thickness testing, hydrostatic testing and other measures.
Original operating and maintenance manuals and procedures were reviewed and updated.

Lessons learned from case study. This model case demonstrates how good planning and effective technical applications can bring major benefits to an existing process plant through low-cost, fast-track execution. Several important lessons can be taken away:

A test run, followed by a comprehensive feasibility study, is essential at the beginning of any debottlenecking project. A test run after each debottlenecking stage is also necessary to assess the performance of the completed stage and to fine-tune the plan for the next stage.
Troubleshooting of longstanding problems is one of the prime requirements for success in any debottlenecking program. The upgrade and replacement of old and outdated processes and equipment with safer and more efficient items should be considered wherever techno-economic justification favors it.
Since debottlenecking is a brownfield job that is performed, in most cases, without completely interrupting the operation of the existing plant, thorough planning is important to minimize hot work. This can be accomplished by taking advantage of the plant’s scheduled shutdown windows.
For extensive debottlenecking programs, the execution schedule should be broken up into multiple stages, instead of one long program. This structure allows early economic returns from the work already completed. It also minimizes production loss and the risk of working inside the live area. Additionally, breaking the project into stages allows work items that require procurement of long delivery components to be executed in the later stage(s).
Recertification of equipment and piping should be minimized by keeping their original design conditions unchanged (e.g., pressure, temperature, etc.) and by avoiding hot welding. Only available cleats, rings, hangers, etc. should be used for modification.
Accommodation of new equipment per engineering standards and practices in already congested or modular plants may be a problem. Any issues should be preemptively considered and addressed in the early stages of planning.
Regulatory clearances and requirements should be considered and applied for well ahead of time.

Challenges not to be underestimated. Some seemingly innocuous and trivial challenges may deter debottlenecking ventures, if not addressed early. Examples of such challenges include:

A remaining life assessment of the plant should be performed at the beginning, to justify any major additional financial stake and long-term expectations.
Before launching the debottlenecking project, the availability of reliable and up-to-date engineering drawings, documents and specifications (i.e., process flow diagrams, piping and instrumentation diagrams, line lists, layout and piping drawings, quality assurance and quality control documents, etc.), depicting all past changes for the existing process plant, must be ensured. Missing or incomplete documentation may become a major issue later on, requiring substantial time and cost to collate and/or recreate them.
Additional raw materials, chemicals and other resources needed to run the plant at enhanced capacity should be assessed and arranged in advance.
Last, but not least, a successful debottlenecking project should conclude with the updating and consolidation of all drawings, manuals and engineering documents reflecting “as-built” condition. This process is important in brownfield projects like debottlenecking. Plant personnel should have reliable resources within their reach to run and maintain the plant safely and smoothly, long after the project team and contractors have left the site. The old drawings and documents should either be destroyed or clearly stamped “void” or “superseded,” and put out of circulation.

Noise Studies

What are Noise Studies?

Noise studies involve the analysis of sound sources and their impacts on the surrounding environment. These studies assess noise levels, predict their propagation, and recommend effective control measures. Noise studies are essential in industries where sound can impact human health, wildlife, or overall environmental quality. By conducting noise studies early in a project, engineers can integrate noise control strategies into the design, leading to cost-effective and efficient mitigation solutions.

Critical for Cost-Effective Solutions: Noise studies identify practical, economical solutions for noise control, minimizing disruptions.
Analysis of Noise Sources and Impact: Elixir Engineering conducts in-depth studies to analyze noise sources and their environmental impacts.
Custom Noise Mitigation: Detailed studies include noise modeling, enabling the design of tailored solutions to meet specific acoustical needs.
Proactive Approach to Noise Control: Early-stage noise studies allow for the integration of noise control into the project design and schedule, ensuring high performance and cost efficiency.
Prevention of Future Issues: Incorporating noise control early helps avoid operational problems and cost overruns associated with noise complaints.
Comprehensive Noise Mapping: Mandatory for various project stages, including pre-construction, construction, post-construction compliance, and complaint resolution.
Industry Experience: Elixir has conducted noise studies across diverse sectors, including oil & gas, mining, power generation, real estate, and entertainment.
Expertise in Equipment Noise Control: Specialized in mitigating noise from a wide range of equipment, including drilling rigs, compressors, pumps, generators, and construction machinery.

Want to learn Noise Studies in Practice?

Explore our Case Studies to see how Noise Studies is performed

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Elixir’s acoustic specialists have completed hundreds of projects across multiple industries.

Construction and demolition
Electrical generation, transmission and distribution, including renewables
Industrial
Oil and gas

We can perform all acoustics tasks, including:

Compliance demonstration documentation
Expert testimony
Field measurements
Mitigation design
Predictive modeling
Regulatory and community interaction

Examples of Noise Studies:

Environmental Impact Reports (EIR)
Environmental Impact Statements (EIS)
Code Compliance Surveys
OSHA Noise Studies
Indoor and Outdoor Noise Studies

Mitigation Design Plans We use industry-leading sound level meters (ANSI S1.4 type 1 certified) for field measurements.
We perform predictive modeling using CadnaA and CadnaR, SoundPlan and others based on best practices for each industry.
Our team creates 3-D noise models of a facility and surrounding areas, based on equipment-specific noise data, field measurements and geographical information.
The modeling allows our team to quickly evaluate noise impacts for various acoustical scenarios and mitigation options at on-site, property line or far-field locations.

Ergonomic Assessment

What is Ergonomic Assessment?

An Ergonomic assessment (also known as an ergonomic risk assessment) is an objective evaluation of workplace conditions to identify and measure the risk factors that may cause musculoskeletal disorders (MSDs) or injuries. It aims to improve workplace safety, reduce injury risk, and enhance employee comfort and productivity.

Key Points:

Purpose:
To evaluate risk factors in the work environment that may lead to musculoskeletal disorders (MSDs) or workplace injuries.
Benefits:
- Reduces absenteeism caused by back pain and other MSDs.
- Improves overall workplace wellness and comfort.
- Promotes a safer, injury-free work environment.
- Provides data for targeted interventions to reduce injury risk.
Process:
The assessment involves identifying and quantifying ergonomic risk factors to recommend improvements that enhance worker safety and comfort.
Workplace Modifications (Office):
- Standing desks to reduce sitting time.
- Adjustable chairs and workstations to improve posture.
- Footrests to support leg positioning.
- Ergonomic keyboards to prevent wrist strain.
- Lumbar support for better back posture.
Workplace Modifications (Industrial/Manufacturing):
- Anti-fatigue standing mats to reduce leg strain.
- Adjustable workstations for optimal body positioning.
- Occupational therapy for injury prevention.
- Posture training to improve neck and shoulder alignment.

Performing an ergonomic assessment provides a clear framework for making data-backed changes that enhance safety and reduce injury risk in both office and industrial settings.

Steps for Conducting an Ergonomic Assessment in the Workplace

At its core, conducting a successful ergonomic assessment is a simple process: Evaluate the work environment and evaluate how your workforce interacts with that environment. Of course, there’s more to it than that. But you should keep these broad goals in mind as you begin your ergonomic assessment so that you can analyze the specifics without getting bogged down in irrelevant details. Here are five foolproof steps for performing a successful ergonomic assessment:

1. Review any Existing Data

The first step to any ergonomics assessment is to take a workplace history and ensure that you understand your baseline. Look at claims data, workplace injury reports, worker’s compensation reports, first aid logs, and any other data you have available to become familiar with any work-related injuries or other incidents that have occurred at your workplace. As you’re reviewing this data, identify any higher-risk activities or departments as well as common injuries and complaints. This will help you focus your ergonomics assessment and improvement efforts on areas where you will see the most results.

2. Choose your Tools

During the final three steps of your ergonomics assessment, you’re going to gather and analyze current data about your workplace and workforce. Before you do this, it’s important to take a step back and determine how you will measure this data. Fortunately, you don’t have to invent these ergonomics measurements on your own. There are well-respected ergonomics assessment tools available in the public domain that have been developed by organizations such as the National Institute of Occupational Safety and Health (NIOSH). Here are some of the best available ergonomics assessment tools:

Caution Zone Checklist
Hazard Zone Checklist
The NIOSH Lifting Equation
Rapid Entire Body Assessment (REBA)
Rapid Upper Limb Assessment (RULA)
Liberty Mutual Manual Material Handling Tables (SNOOK Tables)
Hand-Arm Vibration Calculator (HAV)

Most of these tools are easily accessible online and several have now developed mobile apps as well. Choose the tools that apply to your workplace or facilities and use these as the basis for gathering your objective data.

3. Gather Subjective Data

Rather than jumping right in with your chosen tools and measuring ergonomic risk factors, we recommend starting with a hands-on, subjective evaluation of your current workplace. Begin by walking the floor or the offices to get a real-life understanding of the environment your employees are working in and making notes about any problem areas you see. Remember to be critical and look at your workplace the way an outsider might see it—come to it with fresh eyes. During your walk-through, pull employees aside for a quick conversation about their working conditions. By involving your employees in the process, you can increase the likelihood of early buy-in and support for any future changes. This step will also yield valuable, first-hand accounts and insights that you may not be able to get in any other way. Be sure to explain your objectives thoroughly and encourage open, honest feedback. Ask your employees questions such as:

Does your job involve any repetitive motion?
How often do you experience pain or discomfort while on the job?
Do you get tired while performing your job?
Do you ever feel unsafe while performing your job?
Can you think of anything that would increase your comfort, energy, or feelings of safety while at work?
If you were me, what would you do to improve the work environment?

In addition to face-to-face conversations with individual employees, larger workplaces may want to conduct an employee comfort survey to gather more direct feedback.

4. Gather Objective Data

After you’ve reviewed your work injury history, walked your workplace, and solicited direct feedback, use all of that information to develop a prioritized list of work activities and departments that you need to evaluate. Use the ergonomics assessment tools you’ve chosen to measure your risk factors and complete your objective evaluation.

5. Analyze All Data and Prioritize Risk

Finally, pull all information and insights together to create a prioritized list of risk factors and risk reduction opportunities. Analyze your existing data as well as the new subjective and objective data you gathered during the assessment in its entirety and by task and department. Identify key insights and opportunities for risk mitigation, and prioritize these opportunities by the potential for injury and injury severity. We also recommend identifying areas for short-term and long-term impact. Once you’ve completed these five steps, you’ll have developed a thorough, actionable report of all ergonomic risk factors. You’re ready to create a strategy to reduce these risks and improve the ergonomics at your workplace.

The need of Ergonomic Workplace Assessment

Poor working postures, repetitive tasks and heavy workloads can lead to increased risk of workplace injuries. An ergonomic workplace assessment can identify these risk factors by using a variety of data capture and risk assessment tools.

By undertaking an ergonomic workplace assessment, COPE can assist you reducing the risk of injuries and accidents to your employees, improve productivity and improve organisational wellbeing.

Why Undertake An Ergonomic Workplace Assessment?

By performing an Ergonomic assessment, your business can benefit from:

Prevent costly litigation
Comply with health and Safety citations
Decrease injury risk, error rates and lost working days
Increase efficiency and productivity
Provides a fast assessment that offers practical solutions
What does an Ergonomic Assessment Consist Of?

We will send a skilled Chartered Ergonomist to conduct a detailed workplace ergonomics survey or assessment using appropriate and relevant risk analysis tools. These tools include assessment tools like:

RULA – Rapid Upper Limb assessment
REBA – Rapid Entire Body assessment
MAC – Manual Handling Assessment Charts
ART – Assessment of Repetitive upper limb Tasks

The ergonomist will then present the findings in a written report and identify wider issues for further study. The recommend ergonomic interventions are prioritised by “most gain/least cost”.

We can also assist with implementation of changes either by the organisation itself or with additional input from engineers, designers, industrial hygienists, etc. Help with ongoing trials and evaluation of effectiveness of improvements.

Hydraulic analysis

Hydraulic analysis refers to the technologies to measure, analyze and investigate the water current, water quantity, water pressure and other items in water pipes, pipelines and rivers, etc. In the case of water pipes, for example, the water flows that complexly change in accordance with such influencing factors as the pipe diameter, the length of conduit lines and the number and shape of the branches are clarified by verifications through numerical calculations, analysis models and simulators, etc.

Elixir Engineering the expertise and facilities for undertaking detailed hydraulic studies incorporating:-

Surge analysis and dynamic simulation of pumped pipeline systems and networks.
Preparing conceptual hydraulic designs, to advise on optimum pipeline routing and sizing, equipment selection and operating philosophy.
Pump selection and optimisation of wet well volumes, with switching levels, to minimise the number of pumping cycles and reduce energy costs.
Air valve selection and calculation of pipe diameters with gradients that will ensure stable flow development in drained sections of descending pipelines.
Trouble shooting on-site, with transient flow and pressure measurement/recording.
Feasibility, capital and running cost estimates of pumping and pipeline systems

The analysis results are utilized for piping network designs of water supply and sewage services, river planning for constructing dams and bridges, and flood control and water utilization planning, among other applications. For reservoirs and water channels, pumps and gates can be controlled in an optimum manner based on the data obtained from hydraulic analysis.

In recent years, hydraulic analysis is also utilized for simulating tsunamis (tidal waves) and floods in preparation for mega disasters, as well as for predicting damages from disasters, planning countermeasures and preparing disaster prevention maps.

Pulsation Studies

Pulsation study, mechanical review and frequency avoidance analysis, forced response analysis (as required); according to API 618 / API 674, API 688 and International Best practice guideline.

A pulsation study by Elixir Engineering goes far beyond examining your pipes. Complex compressor systems are subject to comprehensive influences that must be viewed just as comprehensively.

We keep an eye on all excitation and amplification mechanisms. We watch out for overflowing line branches and valves. We consider vortex shedding and repercussions on the piping system. We always react in time, e.g. using optimised pulsation dampeners or by adjusting pipe routing. This way, you will be able to look at your pipes with satisfaction throughout the planning stage and beyond. You’ll always know just what to do.

Studies in accordance with API 618 (reciprocating compressors), API 674 (reciprocating pumps)
Reliable results by calculating gas and fluid-induced vibration over time (adaptive method, non-linearity, etc.)
Quick damper checks and checks of the power unit loading
Investigations on valve dynamics
Structural dynamics calculations (over time) for the mechanical vibration and dynamic stresses on components (mechanical response) to be expected in the piping system
Acoustic simulation of the system after definition of the relevant scope in agreement with the customer
Optimization of the support concept for piping system and vessels
Static pipe stress analysis and reconciliation of the results from the structural dynamic calculations
Consultation in detail planning and implementation, e.g. for flow metering systems

Our pulsation study will enable you to create optimised conditions for performance and service life, e.g. of your machine and can avoid further damage to connected plant parts.

Specialized Engineering Studies | Elixir Engineering Solutions Oman