Project Scope and Cost Development
![Checking calculations and reviewing cost figures [© iStockPhoto.com/Sandor Szabo]](/images/practice-areas/000009164528.jpg)
Our teams effectively develop ideas, either our client’s or our own, into projects that have a strong technical basis and sound financial justification. EFI Group uses a Stage Gate methodology, the goal of which is to minimize technical and financial risks associated with a process or manufacturing facility change.
Streamlined Equipment Reconfiguration for
Advanced Adhesives Manufacturer
EFI created unique designs for novel material loading equipment and fiberoptic light fixtures for an advanced adhesives manufacturer, coming in below the original budget. The work included research, design, and installation of inert 20 mixers loading over 120 diverse powders without adding oxygen. The EFI team developed design standards to streamline installation, and engineered plant utility support systems.
Reduced Costs and Improved Reliability for
Dense Phase Limestone Transport System
EFI’s work enabled a building products client to eliminate $1 million in trucking expenses and increase overall system reliability. Initially, some limestone was traveling 3 miles from quarry to plant via truck, due to the pneumatic transport system’s inadequate capacity. The EFI team designed and supported implementation of a continuous dense phase system, leading to cancellation of the trucking contract two months after start-up. The solution met time, cost, and reliability improvement goals.
Arc Flash Analysis and Implementation
Planning
The client engaged a large electrical firm to perform arc flash analysis (per NFPA 70E) for an aluminum smelting plant. The analysis resulted in a report running several hundred pages, but lacking prioritization or an implementation plan. EFI Group worked with a partner firm to perform detailed analysis on over 100 problem areas, subsequently developing a plan to prioritize and synchronize the numerous electrical upgrade projects. EFI provided project management leading to software models, equipment specifications, and cost estimates to reduce all equipment covered in the original analysis to an Arc Flash Category of 2 or lower, while minimizing plant downtime and implementation costs.
Risk Mitigation for Combustible Dust
Deflagration
EFI designed a strategy to significantly reduce the risk and consequences of combustible dust explosions (deflagration) in a large sugar refinery. EFI continues to work with the customer to improve dust collection and to develop mechanical designs necessary to implement monitoring sensors, magnets and metal detectors, explosion panels, and chemical suppression and isolation systems at various sites.