OVERVIEW

Bajpai Limited can provide Basic Design / Detailed Engineering Services during execution of Projects, covering the following areas:

1) Civil Foundations

2) Pre-engineered and RCC Buildings

3) Steel Structures and Pipe Bridges

4) Soil investigation and topography services

5) Mechanical design of pressure vessels, heat exchanges, vessels coolers/condensers, reactors, absorption columns, driers and other process equipments.

6) Piping Design and Engineering

7) Instrumentation and Electrical Design/Engineering

8) Safety Engineering.

Bajpai Limited’s team of experienced process engineers take up scale-up and Basic Design / Detailed Engineering of Process Plants from Pilot Plant level or proven Technology Level to world-scale Plant Level by close interaction with the scientists involved in process development.

Our basic engineering would include development of P&I diagrams, equipment sizing, optimization and preparation of manuals etc.

Bajpai Limited’s scope in Detailed Engineering would cover all necessary engineering work required for procurement and installation of reactors, vessels, piping, utility systems, electrical, instrumentation, civil works etc.

SOFTWARE

Bajpai Limited possesses extensive in-house expertise to carry out basic and detailed engineering work for industrial and engineering projects.

DESIGN / ENGINEERING STANDARDS

CODES AND STANDARDS

a) GENERAL

Health and Safety Standards according to international norms.

b) MECHANICAL

Materials according to ASTM
Pressure vessels and heat exchangers according to ASME and TEMA
Piping according to API.
Tanks as per API.

c) ELECTRICALS

NEMA, ASA, NEC, IEEE
IEC Recommendations
IP Electrical Safety Code, Part 1.

d) INSTRUMENTATION

ISA-S 5.1 (1973)
API RP 500
NEMA
The Plants shall be equipped with Distributed Digital Control System (DCS) based Electronic Control Instrumentation.

CIVIL / MECHANICAL / STRUCTURAL DESIGN AND ENGINEERING AND PROJECT MANAGEMENT SERVICES:

Bajpai Limited can provide the following services.

1. DETAILED DESIGN OF CIVIL FOUNDATIONS.

Bajpai Limited carries out Civil Foundation designs based on the most up to date International practices.

2. DESIGN OF BUILDINGS & CIVIL INSTALLATIONS.

Buildings and Civil Installations are designed by Bajpai Limited evolving unique concepts and following most modern engineering practices.

3. DESIGN OF PRE-ENGINEERED BUILDINGS (PEB’s)

4. DETAILED DESIGN OF STEEL STRUCTURES AND PIPE BRIDGES.

Bajpai Limited executes the analysis and design of structures from above ground member’s down to earth structures. Computerized structural programs are utilized to include any load combinations that might prevail. Follow up during construction is provided to ensure conformity with the construction drawings and sound construction practices as per the applicable codes.

5. SOIL INVESTIGATION AND TOPOGRAPHIC SURVEYS.

ACTIVITIES RELATED TO SOIL INVESTIGATION AND TOPOGRAPHIC SURVEYS

Site Reconnaissance / Walk over survey
Preliminary Ground Investigation
Installation of Soil Sampling Equipment
Main Ground Investigation
Laboratory testing

Bajpai Limited’s Geo-Technical Reports on Soil Investigation and Topographic Surveys include:

MECHANICAL DESIGN / ENGINEERING SERVICES

Bajpai Limited carries out the complete Mechanical design / engineering of Process Plants including the below noted key activities.

1. OPTIMIZED PLANT LAYOUTS

Highly Optimized Plant layouts are designed keeping in view the Pre-requisites of minimal Piping, Equipment approachability and ease of maintenance.

2. STATIC EQUIPMENT & ROATATING MACHINERY

PRESSURE VESSELS & BOILER SYSTEMS

ASME / API / JIS / ADM / BS standards are followed in the design / engineering of pressure vessels and tanks

REACTORS

Bajpai Limited is specializes in design of “Plug-flow Reactor” and “Adiabatic Reactor”.

HEAT EXCHANGERS / CONDENSERS / COOLERS

TEMA – C and TEMA – R design based Heat Exchangers and Non TEMA Exchangers are engineered by Bajpai Limited including Finned Coolers and Plate & Frame Exchangers. The range also includes surface condensers.

MASS TRANSFER EQUIPMENT INCLUDING ABSORPTION COLUMNS AND DISTILLATION COLUMNS

All types of Mass Transfer Equipment are designed and specified.

TANK, SEPARATORS AND KNOCK OUT DRUNKS

Tanks are designed in full conformance with API Standard.

COMPRESSORS / BLOWERS / FANS / DRIVE TURBINES

Centrifugal, Reciprocating and Rotary Machine are appropriately specifies and designed commensurate with process requirement

PUMP / MOTOR SETS

All types of Pumps Motor Sets (Reciprocating / Centrifugal / Rotary) are designed and specified following API Standard.

PIPING ISOMETRICS

Isometric Drawings for Individual Piping looks comprising the process plants and related utilities with precise specification of Bills of Materials (BOM) and Bills of Quantities (BOQ).

4. STRESS & FLEXIBILITY ANALYSIS

Complete Stress & Flexibility Analysis of piping loops is carried out before embarking on the “Piping Procurement Process” shown above.

ELECTRICAL / INSTRUMENTATION DESIGN ENGINEERING

Electrical Design / Engineering works encompass the following: Entire electrical network including Power Intec and Distribution System.
H. V. Switch Gear
Transformers
Power Control Centers
Motor Control Centers
Emergencies Diesel Generator (DG Sets)
Cable Routings
Control Philosophy etc..

Instrumentation Design / Engineering works encompass the following: Instrumentation Control Loops
Level / Flow / Temperature / Pressure Transmitters
Control Valves
Distributed Digital Control Systems (DCS)
Programmable Logic Control Systems (PLCs)
Uninterrupted Power Supply Unit (UPS)
Control Philosophy etc..

IMAGINARY PHOTOS OF DCS BASED CONTROL ROOM AND OCP FLOW GRAPHICS

BAJPAI LIMITED STANDARDBASIC DESIGN / DETAILED ENGINEERING PACKAGES
The documentation contained in Bajpai Limited’s DESIGN / ENGINEERING PACKAGES shall encompass:
Plant design
Process documents and drawings.
Process technology documents (Know How documents)
Mechanical documents and drawings
Piping documents and drawings
Instrumentation documents and drawing
Electrical documents and drawing
Civil and structures documents and drawing
Project control documents
Mechanical and workshop plans

BASIC DESIGN / ENGINEERING

PROCESS FLOW DIAGRAMS
The Process Flow Diagrams (PFDs) will show operating parameters for both main process plants and utilities

PIPING AND INSTRUMENT DIAGRAMS
Piping and Instrument Diagrams (P & IDs) for both Aqueous Formaldehyde (AF-37) and Paraformaldehyde Process Unit and related Utilities

EQUIPMENT LIST
List of all Equipment / Machinery / Materials and Basic outline Specifications.

INSTRUMENTATION
Instrument data sheets

OPERATING MANUAL
Detailed “Process Operations Manual” including process description, pre-commissioning / commissioning procedures, start-up / normal operation / normal shut-down / emergency shut – down procedures and other pertinent details.

DETAILED ENGINEERING

PLOT PLANS
Overall Plot Plans and Individual Plot Plans of all process and utility sections.

EQUIPMENT DRAWINGS
Detailed Drawings
Mechanical specifications and data sheets for all equipment.

PIPING Piping arrangement drawings
Isometric drawings as required
Pipe sketches
Bill of Quantities

INSTRUMENTATION ENGINEERING
Instrument specifications
Loop diagrams
Single Line Routing Diagram
Terminal Block Diagram
Revised drawings of control room and panels

ELECTRICAL DRAWINGS
Consumer List
Single Line Diagrams
Logic Diagrams
Interconnection Diagrams
Cable routing Diagrams
Installation Drawings
Panel Drawings

GENERAL
Load data for Civil foundations
System drawing for steel Structures with platform and ladders

TYPICAL PLANT LAYOUT BY BAJPAI LIMITED’s 3D ENGINEERING MODEL

HAZOP STUDIES

Bajpai Limited has a cell for safety engineering covering HAZOP studies, disaster planning and related engineering to incorporate safety of plant and personnel.