OSHA first instituted its Process Safety Management requirements in 1992. The official designation in the regulatory code is OSHA 1910.119. This code identifies fourteen (14) elements that are required to be implemented at facilities that exceed a threshold of HHC (Highly hazardous chemicals). EN provides our clients expertise and support in all fourteen elements. In particular, we have professionals who lead Hazardous Operability Studies (HAZOPs) as a part of Process Hazard Analysis (PHA) element. We also provide services in develop Mechanical Integrity (MI) and Process Safety Information (PSI) programs.
The benefit of phase gate engineering in the industrial and manufacturing sector is building a controlled sequence of customized processes and testing for a specific line or plant facility. Putting phase gate collaboration in place helps large teams or departments invite ideas and participation in the ideation stage. Facilitating this process requires leadership in industrial and manufacturing settings, especially where stakeholder involvement and buy-in is concerned. Having an objective partner to guide these challenging relationships and decisions is advisable. The principle goal is to fully evaluate and establish a project scope in the initial phases. Making changes early on in the project has a lower impact on cost as opposed to making a change later in the project lifecycle. EN Engineering excels in documenting progress through phase gate engineering and reports for all those invested in the process. EN engineers nationwide team includes experts in structural, electrical, chemical, civil, mechanical, engineering.
Keeping ahead of industrial maintenance costs through maintenance and reliability engineering means establishing loss elimination, risk management, and Life Cycle Assessment Management (LCAM) strategies. These help determine Total Cost of Ownership (TCO) and Life Cycle Cost (LCC) with industrial assets. Establishing a plan to identify where loss and repetitive failures occur is where the expertise of EN Engineering proves most valuable to our industrial and manufacturing clients. Our engineering professionals provide reliability engineering to optimize preventive maintenance programs and increase equipment longevity while maintaining optimal performance.
Successfully implementing an infrastructure upgrade project or facility expansion requires field services and construction oversight. Having expertise on-hand to manage projects from planning through completion calls for diverse skillsets that aren’t often available in-house. We back that expertise with GIS and mapping services, land surveying, procurement, cost estimating, and automation to offer field services and construction oversight. Our staff includes many of the nation’s leading specialists in fields such as metallurgy and pipeline protection, power and substation design, gas and energy permitting, and compliance. All these certified technicians are available as needed to meet specifications in third-party and regulatory inspections.
Completing projects on budget and on time is much more predictable with the right expertise on-hand to direct the process. Industrial and manufacturing companies turn to EN Engineering for project management that begins with a broad and comprehensive perspective on how projects succeed in planning, budgeting, and scheduling. These best practices stem from our work as a nationwide company staffed by leading experts in industrial engineering. We provide a full spectrum of project management services from facilities design to process management, all ‘right-sized’ to your organization’s scope and scale.
Process Safety Management
The EN safety management systems team of professionals is well rounded, and many of them have worked on the owner’s side, giving them a unique perspective and ability to understand client concerns. These expert consultants can help develop and implement an entire program or evaluate and improve existing PSM programs for safe operations and compliance with PSM standards. We also offer many additional services, including process safety information, process hazard analysis, compliance audits, operating procedures, training, mechanical integrity, incident investigation, PSM program development, and risk management program development.
Process Hazard Analysis (PHA)
Our consultants have the knowledge and expertise to facilitate and lead your process hazard analysis (PHA) in your efforts to enhance the safety of your operation. We have highly trained facilitators and leaders with backgrounds in various industries which require PHAs to be performed. Services that EN offers in connection with PHAs include evaluating various systems and processes, setting of software to define the scenarios, identifying potential consequences from those scenarios, and identifying causes that create those scenarios. The final step in the PHA process is to generate a report for our clients that outlines our findings and offers recommendations.
Process Safety Information (PSI)
As a part of a process safety management program, process safety information is a service EN offers to our clients to develop the process safety information itself in order to be in compliance with regulations. Our team of experts will do the work necessary to bring your data records information into compliance, whether it is upgrading for an existing pipeline or developing it for a new pipeline. This could include many different items, such as electrical classification, creating process flow diagrams, developing the information for safety systems, maximum intended inventory levels, or process chemistry tables.
Management of Change
To ensure that health, safety, and environmental risks are evaluated and under control before changes are made, a management of change program must be in place for those required to follow process safety management rules. At EN, our expert teams have the experience you need to do this. We gather the data necessary to develop clients’ governance documents outlining the protocols and processes for conducting a MOC. We can also supply staff to support the MOC requests, documentation during turnaround events, or other support requests.
Mechanical Integrity Programs
EN’s expert consultants have extensive experience developing comprehensive solutions for mechanical integrity programs to ensure reliability, safety, and compliance with regulations. With this service, we can support your efforts by developing, implementing, or improving your mechanical integrity program. This generally includes developing or upgrading a written manual or governance document, providing training on how to remain in compliance, developing the inspection and testing protocols, and developing quality assurance protocols.
Layer of Protection Analysis (LOPA)
When making risk management decisions, our clients often choose to partner with EN Engineering for a Layer of Protection Analysis (LOPA). Similar to PHA, we provide a facilitator to conduct a risk analysis. This service includes identifying the highest risk causes and scenarios and putting them through the quantitative method layer of protection analysis to determine the number of independent protection layers required to mitigate or prevent each identified catastrophic consequence. Our facilitators are trained and certified to lead an organization and their team through those processes, to reduce the overall risk of a catastrophic incident.
Cathodic Protection Design
As corrosion specialists, EN engineers can be relied on for cathodic protection design. We are committed to providing designs that will protect your valuable assets, achieve or exceed their design life, reduce interference with third-party assets, and meet all federal and state regulations. We can also help with test station configurations and design, electrical isolation, and station facilities. We have extensive experience with multiple industries including oil, gas, water, wastewater, and electrical utilities. All designs are performed in accordance with NACE, AWWA, and other guidelines as appropriate.
Cathodic Protection Troubleshooting
Avoiding industrial accidents and infrastructure breakdowns is one of the top priorities guided by OSHA regulations, API regulations, and industry standards. The pace and production demands produce challenges that endanger processes and the people in charge of those processes. Identifying and solving real-time problems often requires outside expertise to diagnose trouble while production continues. Or, if shutdowns occur, industrial clients need a fast response and the level of expertise to troubleshoot and get operations back going again. That’s what EN Engineering does best. Our nationwide team, staffed in regional offices, is always prepared to identify and solve industrial challenges as fast as possible.
Cathodic Protection Surveys and Inspections
Surveys and inspections prove that prevention is always better than needing a cure. The EN Engineering surveying and inspection team delivers significant value by identifying cathodic protection issues before flaws or failures cause production interruptions. Our inspection teams document information for API, PHMSA, and state requirements and provide important safety guidance for Management of Change policies. We strongly recommend scheduled surveys and inspections as preventative maintenance rather than budget-busting incidents that disrupt operations and put operator safety at risk.
Failure analysis documents the forces or chemical processes involved in metal failure, joint or value decomposition, and other stress-produced outcomes. When industrial metals reach failure points, it is vital to determine whether the cause is a sudden incident or the product of long-term corrosion, metal decay, or stress. The EN Engineering failure analysis team combines our staff metallurgists, mechanical and chemical engineers in analyzing industrial operations. This comprehensive approach to metallurgical failure analysis delivers information vital to decision-making once the reasons for failure are determined.
Welding Procedure Development and Qualification
A weld’s integrity is a product of operator training, quality of materials, and standard of operations in the field or plant environment. EN Engineering provides welding procedure development and qualification to support industrial operations in manufacturing, power and utilities, gas, and renewables. Guiding industrial associates in Welding Procedure Specification (WPS) is one of many services offered by EN Engineering to train welders in alloys and applications specific to their industry and assignment.
Engineering Critical Assessment (ECA)
Industrial operations seeking assurance on the quality of welded structures benefit from the Engineering Critical Assessment (ECA) services provided by EN Engineering. Our team of metallurgists and engineers analyzes the production history of exposed and internal metals to determine the stress history and document flaws in performance and conditions. These assessments of welds are conducted either during downtime or when the structures in question are in use. EN Engineering offers ECA analysis conducted by leading metallurgists in industrial operations, power and utilities, petrochemical industries, gas, and renewables.
Fitness for Service
Fitness for Service (FFS) in the industrial context identifies the condition of existing infrastructure in metallurgical integrity and continued use. EN Engineering conducts Fitness for Service inspections to identify existing flaws, damage, or risk factors impacting industrial metals, welds, and other infrastructure. The outcome draws on tests and criteria specific to regulatory standards. These regulatory requirements evolve based on nationwide incident response and may vary considerably between industries. That is where the Fitness for Service expertise of EN Engineering pays special dividends, as our national experience and real-time exposure to regulatory changes and requirements assure that your facilities meet all safety and operational standards.
Material selection is the science of determining which metals are best suited for industrial infrastructure, piping, machines, and delivery mechanisms. The metallurgical specialists at EN Engineering can assess material interactions and metals’ chemistry down to the nanoscale to help industrial producers make decisions that lead to better performance and safety in their operations. Our metallurgical specialists are leaders in the field, collaborating with private/public projects and academic researchers to bring new insights to industrial material selection.
Piping and Component Stress Analysis
Piping and component stress analysis provides an assessment of expected performance in the course of its use. Testing and measuring anticipated stress is a standard procedure that affords value in documenting this infrastructure’s original working condition and its relative response as designed and installed. EN Engineering piping and component stress analysts conduct tests on pipe and component flexibility, pressure response, metallurgical integrity, and potential degradation over time. This real-time analysis provides foundational data for maintenance, decision-making, and upgrade or replacement strategies as needed.
Pipe and Fitting Specifications
Pipe and fitting specifications established by ASME (American Society of Mechanical Engineers) apply to all industrial uses. Identifying the appropriate size and fitting for each industrial application is one of the valuable services provided by the mechanical and industrial specialists at EN Engineering. The safe installation of construction pipe and fitting benefits from front-end knowledge of metallurgy, material selection, welding procedure development, and best installation practices. When completed, a component stress analysis is required to determine the quality of the finished product.
Moving document storage from paper record-keeping to digital formats is a service provided by EN Engineering to help industrial organizations move from processes that hold them back to practical, progressive data formats useful in operational planning and management. Once data is converted through document digitization, it informs the measurement of past performance. That capability allows a broad-spectrum study of any flaws, failures, or performance interruptions over time. With cloud capability and document democratization, the converted data is available at the touch of a key rather than sifting through folders or even losing documentation to filing errors, accidents, or other incidents. EN Engineering takes care of the document digitization process so that your firm is better empowered about its past and its future.
Data Conversion and Reconciliation
Data conversion and reconciliation is a service provided by EN Engineering to corroborate and correlate the verity of all data drawn from prior record-keeping. We stress data conversion by comparing digitized information against its sources to determine any flaws, missing records, incorrect data, poor formatting, or quality of conversion. These steps prepare data for use in future analytical studies. This service’s value is the data’s usefulness in determining the effects of change in processes and efficiency of mechanical and operator interactions.
Data Cleansing and Verification
The process of data cleansing and verification eliminates bad information, specifically corrupted formats, disrupted tables, redundancies, and inaccurate records. EN Engineering data specialists use progressive software technology to comb through data conversion and reconciliation files to deliver purified information in preparation for use in analysis, planning, and implementation of processes such as Mechanical Integrity Programs (MIP) and Management of Change (MOC).
Once data best practices are established, and data integrity measures are in place, data maintenance takes over as the top priority in industrial applications. Testing the flow and quality of data is critical to its integrity and usefulness, both in real-time and over the long term. EN Engineering data maintenance consultants help industrial clients implement best practices to ensure consistent, reliable data production and storage. Data quality also fuels intelligent Process Safety Management (PSM) and enhances productivity studies and analysis. Data maintenance determines its value for all such purposes.
Mobile Data Collection
Mobile data collection is vital to real-time operations with a workforce on the move or working remotely. The capture, storage, and distribution of qualitative and quantitative information generated by mobile data inform industrial processes in real-time. Determining the best mobile tools for your organization is the foremost priority. Structuring and formatting mobile data is the next step. Building and testing collections apps also impact a mobile data collection program. Training your team on devices, mobile software, and best security practices are all part of the implementation process. Our turnkey services plug your mobile field assets into the data collection flow for optimal performance.
Imagery Analysis and Information Extraction
Imagery analysis and information extraction through software tools such as ArcGIS Pro have transformed industrial planning from traditional landscape and infrastructure survey to specifically actionable data drawn from high-resolution images. The specificity and actionable data gathered through these processes are superior and exceptional in its applications over traditional visual inspections. Analytic maps are useful in modeling every aspect of topography. EN Engineering brings the promise of imagery analysis and information extraction to the complex needs of industrial planning.
Custom Spatial Analysis
Custom spatial analysis dials in information vital to understanding the relationships between structures and topography. These processes enable specific, data-driven comparisons to study a given site’s suitability for its intended purposes. Spatial analysis delivers layers of information critical to site-intelligent decision-making on environmental conditions and structural integrity. That level of insight determines site feasibility, risks, and accommodations related to grades, elevation, and consistency of existing landforms and features. EN Engineering conducts custom spatial analysis to deliver high-quality information to new and expanding industrial facilities to predict and control otherwise unanticipated factors.
Industry Modeling and Trend Forecasting
The specifics of industry modeling and trend forecasting depend on the quality of data available from the source organization and the external data available for comparison modeling and predictive analysis. With a nationwide reach and clients in multiple industries, EN Engineering brings vital perspectives to industry modeling and forecasting practice. Our consulting teams develop big picture models across economic and market trends using automated competitive data and business intelligence software. It is often the granular data of production efficiencies, regulatory and environmental impacts, material supplies, procurement channels, and innovation that determine industry and manufacturing companies’ ultimate success. Our role is to provide our clients with the right form of data and provide investment options in capital or process improvements.
Data System Strategy, Design, and Optimization
It’s essential to gather and maintain quality data, but having a data system strategy to organize and employ business and operational information determines industrial data’s ultimate value. The design and optimization of a data system strategy depend on understanding which data is critical to measuring mechanical systems and processes’ effectiveness. EN Engineering collaborates with industrial clients to identify these data categories, design a data system strategy, and organize data optimization across all operations.
Data Integration Planning
Data integration planning is the process of driving more efficient plant operations by building data flow models to form a single, consolidated whole. That requires a thorough assessment of all data sources, even manual operators. Once data sources are established, integration analysis can take place. EN Engineering software specialists assist organizations in surveying and aggregating this data into a single stream of consolidated data. We test data for consistency and accuracy, conducting assessments to calibrate formatting and develop plans for access and distribution to all stakeholders.
Workflow Integration and Analysis Modules
Workflow integration brings automation to bear in industrial applications. This method draws together information from selected databases and software systems to bring formerly siloed data into an accessible whole. Workflow integration and analysis modules can also capture logistics and distribution patterns, material supply levels, pricing and procurement, billing, payroll, and accounting. EN Engineering provides the expertise to collaborate with IT and operations managers to establish workflow integration and analysis modules.
Custom Analysis Tools
Custom analysis tools to study and manage industrial infrastructure, mechanical operations, systems, and processes are becoming far more prevalent in the age of data-driven decision-making. In collaboration with IT teams and internal managers, EN Engineering helps industrial clients identify production and profitability priorities where intensive qualitative and quantitative data delivers the most value. Our experience with state-of-the-art software strategies, including MES (Manufacturing Execution Systems), enables EN Engineering to develop and apply custom analysis tools at every operation scale. Gathering and interpreting targeted data brings hidden problems to light, including their source and level of risk. Custom analysis tools help industrial facilities hunt down potentially dangerous and expensive issues that threaten operational safety and production. EN helps industrial clients troubleshoot, problem solve, and put custom analysis tools to use where they are most needed.
Running the numbers on risk assessment is both a physical and actuarial process. The first thing an industrial company needs to know is where their risks commonly occur. As a nationwide consultant engaged in industrial engineering and risk assessment across various industries, EN Engineering offers exceptional insight and software solutions to conduct risk assessment from the macro to micro-scale. We help our clients pull together data pertinent to risk assessment, identify potential blind spots, spot flaws, and document incident records. From there, we build analytical and predictive models that industrial companies need to improve operations, increase safety, meet regulatory compliance, and plan for the future.
Program management in the industrial world typically draws on engineering, data systems, and change management to improve operations in some capacity, even the whole organization. To accomplish these aims is problematic from the inside. Managers responsible for day-to-day production seldom have time to extract themselves from operational responsibilities to conduct the planning and analysis necessary to establish a specific program management plan. Even identifying program management priorities can be difficult with associates whose tenure and pride in their work eclipses vital objectivity. EN Engineering excels in navigating these hurdles to assist industrial companies in choosing where to put their efforts and put program management plans in place. We also bring automation, software technology, systems analysis, and extensive safety and regulatory requirements to bear in program management. Our turnkey approach takes industrial clients’ burdens by providing managerial vision and project oversight to create a thriving environment for all involved.
Dashboards and Reporting
Dashboards and reporting may sound like incremental tools involved in day-to-day operations, but developing a consistent interface for operators and managers is one of the keys to consistent communication. The priority is to identify the most common functions and determine how to automate and highlight them for ease of use and user error reduction. Data produced through clearly defined dashboard functions is more accessible to aggregate and study. Reporting becomes more straightforward, and operators are not distracted by background information that is not pertinent to their job. Enhancing dashboards often means simplifying them. EN Engineering software and hardware specialists drive clear understanding and communication.
IT Project Management
IT departments typically have their hands full in keeping industrial operations running full-speed and secure. When new demands arise, the time available to push the agenda forward isn’t always there. The IT project management team from EN Engineering offers the expertise to study equipment and software upgrades’ value and develop implementation plans. That includes ideation and planning, budgeting, execution, and rollout. With so many productivity outcomes dependent on successful IT operations, industrial and manufacturing companies benefit from IT project management at every scale.
GIS enhancement is at the forefront of enhancing productivity and profitability for industrial and manufacturing companies. The combination of GIS technology with business intelligence software enables companies to track vital assets and fine-tune production and delivery processes across departments and operations. GIS enhancement tracks company assets from production through logistics and distribution, improving travel and delivery time and communication with suppliers and customers. All these functions provide more accurate data for reporting, analysis, and planning. EN Engineering guides industrial clients in GIS enhancement for greater productivity and profitability.
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