process

Process & Risk Division

litha Project Services’s process engineering and risk consulting team competencies cover the complete range of process engineering services to assist our clients in maintaining a competitive edge in their respective markets. From feasibility studies and engineering through to operations support and commissioning assistance, we customize our services to the Client’s business and project goals.

IPS’s range of process engineering services include process consulting, basic and detail process design, fabrication and construction support, and commissioning services to clients in the sectors of: Oil and Gas (upstream, midstream, downstream operations), Petrochemicals, Energy, Synfuels, including CTL and GTL, and the Chemicals Sectors.

The IPS team has strong process engineering capabilities, particularly in conceptual design and process development. Other areas of specific expertise include process assessments, facility appraisals, feasibility studies, technology evaluations, techno economical analysis, project finance structuring and support and due diligence studies. (see project development and finance)

IPS has also developed specific niche capabilities in the field of environmental engineering. Ilitha is able to complete emissions abatement projects, which may include pollution prevention strategies, emissions inventory studies and emissions abatement technology selection, thereby assisting clients in achieving environmental legislative conformance.

IPS also has competencies in Coal Gasification project development and assessments, Coal to Liquids (CTL) modelling and technology selection.

Process Consulting

• Strategic planning and competitive analysis
• Due Diligence Assessments and Facility Appraisals
• Business Consulting, Economic analysis and Financial Modelling
• Management Consulting and decision-engineering
• Project Framing, Scoping and Design Basis Development
• Conceptual Development, Pre-Feasibility, Feasibility Assessments
• Process Development and Process Integration
• Technology Evaluation and Selection

Process Engineering

• New Process Development
• Process Technology Development and Licensing
• Front-End Engineering Design (FEED)
• Basic and Detail Process Design
• Process support for Procurement, Project Management, Project Implementation and Construction Management (EPC Contracts)
• Process support for Start-up, Commissioning and Performance Testing
• Plant Investigations, Trouble shooting, Debottlenecking, Plant Modernisation and Plant Optimisation
• Process inputs into Capital Cost Estimating (Capex) and Operating Costs (Opex)

Specialist Process Services

• Environmental Emission Abatement Projects
• Coals to Liquid (CTL) Concept Development, Technology Selection & Modelling

Process Safety Engineering & Assessments

IPS has a wealth of experience in the facilitation of various forms of design safety reviews, including HAZOPs, SIL target assessments, Preliminary Risk Assessments and Project Risk Assessments.

• Safety Studies, Due Diligence Studies, and Third Party Safety Reviews
• Project Risk Assessments
• Basic Design and Operability Reviews (BDORs)
• Preliminary Hazard Assessments (PHAs)
• Hazard and Operability Studies (HAZOPS)
• Safety Integrity Level (SIL) Target Assessments
• Incident Cause Investigations
• Process Safety Management System audits

IPS has conducted Safety Engineering work both locally and internationally, primarily in the Oil and Gas (upstream and downstream), Petrochemical, Oil Refining, Mining and Nuclear sectors.

electrical

Electrical Division

Ilitha Project Services provides specialist services in the electrical field, with our engineering and design conforming to the highest standards required in industry. The team consists of registered professional engineers. We utilise CAD systems during our design process and our rigorous checking and auditing system ensures that safety in the electrical designs is never compromised.

Our range of specialist electrical services include:

• Medium & Low Voltage Reticulation
• Substations
  • Design of new substations from base principals
  • Re-design and optimisation of existing substations
  • Upgrade and revamp of exsiting substations
• Uninterruptible Power Supplies
• Motor Control Centres and Drives
• Lighting design
• Earthing & Lightning Protection
• Electrostatic Precipitator Services
  • Precipitator control system optimisation
  • Precipitator control system fault finding
  • Precipitator electrical maintenance and operation strategies, which would include Maintenance Tech Specs on all equipment, OTS and test procedures
  • Electrical audits on all electrical aspects of the precipitator and report generation of findings and recommendations
  • Process management system strategy for all units (example is the PMS at Eskom Lethabo and Kendal power stations)
• On-line diagnostics such as VI curves and rapping frequency modelling – optimisation of the individual fields.
• Hazardous Areas Compliance studies.
• Implementation of electrical SCADA monitoring systems.

automation

Automation Division

The Automation group has experience in the concept and detail design of field instrumentation, ranging from traditional pneumatic to the latest field and bus systems. This includes the correct selection and sizing of instrumentation for the required applications.

The Automation group also has a wealth of experience in the implementation and integration of control systems in environments where high reliability and availability is required. This includes the latest DCS systems and SCADA and PLC systems in various environments.

Integration of any type of field instrumentation utilising conventional 4-20mA interfaces, Fieldbus, ProfiBus, RS485, remote i/o systems, Industrial Ethernet, motor control centres, MIS, OPC or other type of interface is one of the key strengths of our automation division.

The team has years of experience in the detail design and configuration of DCS systems in the mining, Iron & Steel, Petrochemical, chemical and manufacturing industries. We have also built core competencies in the design and implementation of ‘hot switchover’ from old legacy control systems to the latest technology DCS and PLC control systems. This is achieved by following a process we have developed to enable us to minimise risk before any physical work commences.

Our range of instrumentation and control services includes:

• Field instrumentation engineering
• Control systems engineering
• Field bus systems engineering
• Safety management systems engineering
• Control & instrument modernisation projects
• Total solution supply for automation applications
• Automation turnkey project execution
• Integration of control systems
• Upgrade & Hot Switchover of control systems

civil

Civil / Structural & Buildings Division

Civil Consulting and Structural Design ServicesIlitha Project Services, in alliance with its associates, provides seamless integration of civil and structural engineering as part of multidisciplinary industrial projects:

• New design of supports, platforms, pump bases, footings for equipment, underground piperacks, sewers
• Interface with other engineering disciplines during design phase of projects
• Civil drafting, including layout and detail civil and structural drawings
• Site assistance and QC of civil work during construction phase

In addition to integrated civil engineering projects, Ilitha also provides stand-alone civil and structural projects:

• Elementary and Complex Structural Steel Factories
• Warehouses and Cold Storage
• Communication Masts

mechanical

Mechanical & Piping Division

Ilitha Project Services, in association with PDPS (Plant Design & Project Services (Pty) Ltd) and other alliance partners, covers the full spectrum of mechanical, piping design and engineering, focussing specifically on the more stringent high-end engineering requirements of the Oil & Gas sector, Refinery and Petrochemicals industries, Synfuels (GTL and CTL) industries, as well as Liquid Fuels Infrastructure and Chemicals sectors.

Piping Design

• Design work can be performed according to ASME, BS, DIN, AWWA, SABS; alternatively to any client-specific specifications. IPS, with its associates, can provide a complete range of piping design services, including:
• Developing piping, valve and piping material specifications to new code requirements and draw up detail piping specifications for new projects.
• Detail pipe design and isometrics
• Re-rating verifications including wall thickness, flange & valve ratings
• Checking to meet Code requirements existing designs
• Design pressure and test calculations
• Nozzle loading to within Equipment Specifications
• Design and Data Sheets for spring supports and special pipe supports
• Stress Analysis using Caesar II software

Mechanical Engineering
Design work can be performed using ASME, BS, DIN, API, AD MERKBLATTER and/or to any client-specific specifications. IPS, in association with PDPS, can provide a complete range of services in the mechanical engineering division which include the following:

design office

Design Office

Our design office has drafting services, providing design support to all of our divisions.

Process Drafting Services:

• Drafting of new PFD and MFD/P&IDs
• Drafting of existing MFD/P&IDs drawings before modifications are done
• As-built (red line) of existing MFD/P&IDs or PFD drawings on site
• Plot Plan layout and Area Classification Drawings

Pipe Drafting Services, in association with Plant Design and Project Services (PDPS) and other alliance partners:

• Detail Piping Plans & Layout
• Approved for Design (AFC) Isometrics including detail Bill of Materials (BOM)
• As-built (Red Line) of existing and PFD’s on site
• Produce As Build piping isometrics, general arrangement drawings, piping layout drawings

Mechanical Drafting, in association with PDPS and other alliance partners:

• Tender Drawings as part of procurement of new equipment
• Equipment location and orientation drawings
• Detail Mechanical Design Drawings (Including plate layouts, vessel internals, weld maps & NDE maps, Spare part drawings