Burt Process Equipment delivered advanced waste management and lift station systems for a pharmaceutical manufacturing facility. These systems were designed to enhance operational efficiency, ensure regulatory compliance, and support seamless integration into the client’s processes.
Industry
Pharmaceutical Manufacturing
Challenge
Complex Waste Management
Solution
Client Profile
The client, a global pharmaceutical leader, required comprehensive wastewater treatment and transfer systems to manage their facility’s complex waste streams. The systems needed to accommodate high capacities, meet stringent environmental standards, and provide reliable performance in a demanding industrial environment.
Client Requirements
The project specifications included:
- High-Capacity Waste Transfer and Equalization: Systems capable of handling significant waste volumes with precision.
- Effluent Monitoring and Safety: Advanced instrumentation for real-time monitoring and waste diversion.
- Integration and Modularity: Skid-mounted systems to simplify installation and operational scalability.
- Durability: Components designed to withstand challenging industrial conditions, including high temperatures and corrosive environments.
Equalization Tank and Transfer Skid
- Tank Features:
- 2,110-gallon single-wall vertical polypropylene tank with a dome top and flat bottom.
- Reinforced construction with flanged nozzles, a 24” side manway, and Endress radar level sensor.
- Pump System:
- Two Price CD stainless steel horizontal pumps (20 GPM @ 30 TDH).
- Plate-and-frame heat exchanger to cool waste from 80°C to 60°C, complete with isolation valves, pressure relief valves, and temperature indicators.
Process Waste Lift Station (SK-866A and SK-866B)
- Tank Specifications:
- 340-gallon 304SS tanks with reinforced supports and welded covers.
- Endress guided wave radar sensors for level monitoring and SS high-level float switches.
- Pumping Systems:
- Two Price 316SS vertical centrifugal pumps (25 GPM @ 60 TDH) with Teflon fume barriers and tungsten-coated shafts.
- Discharge SS ball valves and check valves for reliability.
Control System:
- Panel Design:
- NEMA 4X stainless steel UL-listed control panels with Allen-Bradley CompactLogix PLCs.
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15” VersaView HMI for real-time monitoring and control.
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Features include redundant power supplies, emergency stop relay, motor starters, and Ethernet connectivity.
- NEMA 4X stainless steel UL-listed control panels with Allen-Bradley CompactLogix PLCs.
Modular Skid Design:
- All systems pre-plumbed and pre-wired on epoxy-coated skids with Schedule 10 SS plumbing and corrosion-resistant rigid electrical conduit.
Implementation
Factory Acceptance Testing (FAT):
The systems underwent rigorous testing at Burt Process Equipment’s facility, ensuring all components met the client’s operational and safety requirements.
Startup and Training:
- Three consecutive days of onsite support for system calibration, startup, and training.
- Comprehensive training sessions covered system functionality, maintenance, and troubleshooting.
Field Services:
The client managed offloading, installation, and interconnections between assemblies with guidance from detailed engineering documentation provided by Burt Process.
Benefits
- Precision and Efficiency: Advanced monitoring and automation ensured accurate waste handling and operational efficiency.
- Compliance and Safety: Real-time monitoring and waste diversion mechanisms ensured regulatory adherence.
- Ease of Integration: Skid-mounted systems minimized installation complexity and downtime.
- Long-Term Durability: High-quality materials and components provided reliability in demanding environments.
Outcomes
The integrated waste management systems provided the client with:
- Efficient and reliable wastewater transfer and treatment tailored to their facility’s needs.
- Enhanced compliance through precise monitoring and automated safety mechanisms.
- Simplified installation and maintenance due to modular, skid-mounted design.
Conclusion
Burt Process Equipment successfully delivered a comprehensive solution for the client’s wastewater management challenges. By leveraging innovative engineering and high-quality materials, Burt Process Equipment ensured the client achieved long-term operational success and environmental compliance.
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