Balance-of-plant (BOP)

Balance-of-plant (BOP) engineering to adapt a new nuclear plant to the local conditions, water supply, wastewater requirements, power, and infrastructure requires several experienced engineers and project managers. Leverage the energy of multiple inexperienced engineers with an experienced coach or trainer. Startups with great ideas can fail without adequate design experts and BOP work.

Start-up businesses with an excellent new core technology may require a large amount surrounding engineered equipment including piping, pumps, turbines, valves, instruments, controls, electrical hardware, vessels, steel, and more. I am happy to do balance-of-plant (BOP) work for start-ups or the new nuclear industry.

EXPERIENCE

  • Design and Project Management (PM) for a new powerhouse in Bordentown, NJ. Three 800 HP fire tube boilers were added to an existing building. Items selected were boiler feed water pumps, surface blowdown system, deaerator, softener, condensate polisher, condensate tank, condensate pumps, vacuum condensate system, piping, pipe supports, instruments, and PLC/computer controls. These boilers were the exclusive steam and heat source for the Wagner and Garden State Prisons.

  • The engineering for a Co-generation Plant at Johnson Matthey in Deptford, NJ. This included Process Design and specification of gas turbines, heat recovery steam generators, steam turbines, backup fired boilers, backup reciprocating generators, deaerator, softener, boiler feed water pumps, condensate tanks, PFD, P&ID, instrument index, equipment data sheets, pipe sizing and specification, instruments, LV wiring, and all details for bid package. Project Management included 12kV medium voltage distribution and other tasks with assistance from specialists.

  • Programming and set up of complete Emergency Response Data Systems (ERDS) for three nuclear power plants: Salem 1, Salem 2, and Hope Creek. These are all owned by PSE&G. An unknown custom protocol was investigated and decrypted.

  • Selected the Boiler Feed Water Pumps and made all the necessary calculations for a boiler project at Bayside State Prison. One fire tube boiler was added to the powerhouse.

  • Selection and addition of high-head pumps for condensate recovery and conversion of pumps to steam turbine drivers at Chevron Refinery in Perth Amboy.

  • Led and documented HAZOPS for a Marine Vapor Control System and multiple Refinery Crude Units. Attended other HAZOPS as an equipment and system expert.

  • Designed many control enclosures including wiring, layout, VFDs, SCRs, SSRs, contactors, relays, wireless networks. Successful troubleshooting and repair of legacy controls and instrumentation.

  • Designed chemical feed plants including PFD, P&ID, PSV calculations, hydraulic calculations, pump and instrument data sheets, wiring diagrams, valve lists, start-up. Cryogenic ethylene vaporization system design for HIMEL/Vijay Tanks in India and one ambient chlorine vaporization system for ERCO in Canada.

  • Designed pilot plants for testing twenty automotive sensors using gas composition control and temperature control. Custom designed five associated electric heaters. This was for DuPont in Wilmington, DE.

  • Managed/designed complete new chilled water and tower water system for the four DOT buildings in West Trenton, NJ. New system included cooling towers, two 800-ton chillers, medium voltage distribution and monitoring, all new control valves for the numerous air handlers, primary/secondary/tertiary chilled water piping systems with pumps and VFD flow control, and tower water pumps and controls.

  • Engineer for large water heating system at the Bayside prison in NJ. Many primary and secondary pumps, heat exchangers, radiators, pipe runs, regulators, control valves, pressure relief valves, custom thermal expansion hardware, and controls were successfully installed. This prison was like a city with multiple buildings. The hot water supply piping was 14-inch diameter with 210 °F water.

  • Design Engineer for Ocean Spray Cranberries plant installation in Bordentown, NJ including chillers, cooling tower, potable water filtering and distribution, tower water and chilled water pump systems, water heating, controls, and air handlers.

  • Instrumentation selection and design of over 500 instruments including control valves, flow sensors, regulators, pressure & DP transmitters, thermocouples, current switches, relief valves and rupture disks, controllers, alarms, linearizers, analyzers, I/O cards, and others. About 70 of these instruments were relief devices that were sized and selected. This was for one new alkylation plant at Mobil Oil.

  • Designed five glycol cooling systems and two glycol heating systems on one project, each with independent temperature control. Eighteen heat exchangers, primary pumps, secondary pumps, control valves, expansion tanks, and piping were included.

ADDITIONAL

  • I have experience running an engineering department successfully and as project manager for many engineering and construction projects in the process industry. Willing and able to adapt your "black box" to the local salt water, fresh water, grid, infrastructure, weather, soil, bedrock, regulators, and experts.

  • Design of many heat exchangers using HTRI XChanger Suite software.

  • Technical support and start-up experience for process systems, controls, and heat transfer equipment.

  • Invented the Supercritical Mixer to prevent pipe rupture from turbulent thermal fluctuations.