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Consultancy Services - FERRO ALLOY PLANT – DESIGN, ENGINEERING & EXECUTION
FERRO ALLOY PLANT – DESIGN, ENGINEERING & EXECUTION :
Integrated engineering support from concept and basic engineering through detailed engineering, procurement support, construction, commissioning and performance stabilization.
FGT Consultancy Services provides engineering and project execution support for ferro alloy plants and associated facilities. Our scope can be structured around the complete project life cycle, with emphasis on practical plant design, constructability, equipment integration, site execution, commissioning and safe start-up.
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Overview
DESIGN & ENGINEERING:
• Process flow and plant configuration • Furnace, transformer and electrical system engineering • Raw-material handling, batching and charging systems • Fume extraction, gas cleaning and pollution-control interfaces • Cooling-water, compressed-air and utility systems • Civil, structural, mechanical, piping and layout engineering • Electrical, instrumentation, automation and control philosophy • Equipment specifications, datasheets and technical bid support.
PROJECT EXECUTION:
• Project planning and execution strategy • Procurement and vendor engineering coordination • Fabrication, erection and installation supervision • Mechanical completion and system-wise commissioning • Electrical energization and functional testing • Furnace start-up support and operating stabilization • Trial production, performance monitoring and handover • Shutdown / maintenance and plant improvement support.
Note: The exact process route, equipment configuration and engineering deliverables are selected according to alloy grade, furnace capacity, raw materials, product specification, environmental requirements and client standards.
Execution & Commissioning Methodology:
01 PROJECT PLANNING :Define scope, WBS, engineering schedule, procurement plan, construction sequence, resource plan and interface matrix.
02 ENGINEERING :Freeze process/design basis, issue drawings and specifications, coordinate multidisciplinary engineering and resolve interfaces..
03 PROCUREMENT SUPPORT :Prepare RFQ technical requirements, evaluate vendor offers, review drawings/documents and support inspection/expediting.
04 CONSTRUCTION: Coordinate civil, structural, mechanical, electrical and piping works; monitor quality, safety, progress and work fronts.
05 INSTALLATION :Equipment erection, alignment, piping, cabling, busbar systems, instrumentation, utilities and auxiliary systems.
06 PRE-COMMISSIONING : Inspection, flushing, testing, loop checks, motor solo runs, interlock checks, protection testing and punch-point closure.
07 COMMISSIONING & START-UP :System-wise commissioning, furnace auxiliaries start-up, controlled furnace start-up, tapping/casting system trials and process stabilization.
08 PERFORMANCE & HANDOVER :Trial production, operating parameter review, documentation, training/support and final handover against agreed project requirements.
Ferro Alloy Plant Capabilities :
Engineering and execution support can be developed for ferro alloy projects such as FeSi, SiMn, HC FeMn and other submerged-arc-furnace based alloy plants, subject to the selected technology, capacity and client design basis. Services may be provided as complete project support or as individual engineering, procurement, construction-management, commissioning and plant-improvement packages.