Completed Projects

The following projects are a selection of recent projects that consulting engineer Peter Lumley has undertaken. For more information on past projects please choose the link below. 

Process Industries

List of relevant projects:-

Current

Since 1996 has carried out over 150 site surveys of offshore and onshore oil/gas production and processing facilities (LNG, NGL and LPG separation), refineries (with sulphur recovery units), petrochemical plants. Work undertaken included design reviews and operation and maintenance cost analyses as part of the annual benchmarking studies. Crude oil and petroleum products storage facilities include over 50 marine storage and loading facilities worldwide. Refineries have included all of PEMEX (Mexico) that represents 5% of global refining capacity. Pipelines have included some of the largest pipelines in the world:-Trans- Alaska pipeline, BP’s BTC pipeline Azerbaijan to Turkey, BP`s Forties pipeline system and Destin pipeline in Gulf of Mexico.

Facilities at BP, ExxonMobil, ConocoPhillips, Agip, Statoil, Norsk Hydro, Dong, OMV, Nerefco,Williams Field Services, BHP, Qatar Petroleum, ADMA OPCO (Abu Dhabi), PDO, Woodside Petroleum, Petrofac, Sasol, NIOC (Iran), NCSP/ Dinh Co. (Vietnam), PEMEX (Mexico), British Gas, and Shell.

2018/19

Technical review of facilities including use of CHP steam and power generation at the soda ash plant, Nantwich on behalf of Tata Chemicals Europe Ltd.

2018

Technical audit of the FEED and detailed design on the upgrading of the Pavlodar Refinery on behalf of Rominserv SRL, Romania.

2017/18

Review of piping design, 3-D model and isometrics in respect of claimed design and construction defects and remediation costs on behalf of HFL, Manchester.

2017

Review of over 100 variation claims and quantum on behalf of the JGCS Consortium, in respect to the NSRP new refinery in Vietnam, requiring review of preferential design development comments in regard to HAZOP studies and 3-D models.

2014/15

Technical audit and quantum on design changes, cost overrun by a contractor on produced water filtration skids on an offshore gas processing facility. Required review of preferential design development comments in regard to HAZOP studies, 3-D models and fabrication isometrics.

2014

Reviewed design of LPG/NGL gas refinery in Iran and gave advice on process operating scenarios.

2013

Consultancy advice on piping construction and commissioning of high pressure steam piping at a Biomass CHP power plant.

2011/12

Review and advice on a Gasholder designed to API620 /BS14015 for a major steel mill in Brazil on behalf of Ferrostaal, Essen, Germany.

2009/10

Investigated design and material non-compliances in design and supply of 100 ball valves (6 inch through 20 inch ) for four (total 1400 MW) HRSG steam boilers (steam pressure 104 bar, temperature 565° C) dual fuel natural gas/fuel oil for the Dubai Electricity and Water Authority Power and Desalination Station. Work included FMEA (failure mode and effects analysis) and compliance with ISO 9002 procedures of non- destructive testing of castings for valve bodies..

2008

Reviewed valve and piping specifications and insulation specifications for cryogenic storage and pipe work at South Hook LNG terminal on behalf of CB&I John Brown.

2008

Review and update piping standards for GlaxoSmithKline including advice on material compatibility and insulation specifications and installation.

2008

Feasibility study including project capital and operating cost estimates for gas pipeline and gas conditioning units and specification for supply of new CCGT power station in Nigeria on behalf PKF accountants. Work included interviewing government ministers on energy supply strategy and the market for private investment on new CCGT plants to overcome electric supply shortages in Nigeria.

2007/08

Prepared techno-economic feasibility study, including capital and operating cost estimates, and basic engineering design for 40,000 tonne per annum citric acid plant in Saudi Arabia on behalf the private sector client. Work included provision of all utilities including ultra pure filtration for water treatment, demineralisation plant and effluent treatment plant.

2007

Review of basic design and operational costs for proposed GATE LNG terminal and storage facilities in Rotterdam on of behalf of Gasunie

2006 – 2008

Undertook benchmarking cost analysis for the European Gas Transmission Initiative for all gas pipelines and storage facilities (both above ground and below ground) in Europe. The project required review and analysis of all operating and maintenance costs for pipeline systems, compressor stations and storage facilities for National Grid (UK), BGE (Eire), BEB (Germany), Enagas (Spain), Energinet (Denmark), Gassum (Finland), Gasunie (Holland), GRT gaz (France), OMV (Austria), Snam Rete Gas (Italy).

2005

Preparation of 20 valuations on behalf of the Kosovo Trust Agency for a variety of industrial process plants in advance of their privatisation.

2005

Carried out technical audits of operating and maintenance costs for PEMEX, the Mexican state owned oil company including all their refineries (including sulphur recovery units and LPG production and storage). The refining capacity represents 5% of global refining capacity.

2005

Preparation of due diligence report including review of the basic design and selection of equipment, valves and piping for a mini refinery in Russia on behalf of PKF accountants including assessment of proposed design of water treatment and effluent treatment facilities 

2005

Preparation of the valuation of a cement process plant in Sudan on behalf PKF accountants, London.

2004

On behalf of Brunner Mond, Northwich, undertook an analysis of manning levels and production costs at its Soda Ash plant together with the neighbouring Ineos sodium chloride plant

2004

Preparation of the design audit and due diligence report for loan for the expansion of ammonia production and storage facilities at a fertiliser plant including including review of cryogenic process plant and storage facilities and enhanced capacity of water treatment and effluent treatment facilities. Identified and prequalified prospective contractors.
Client: ACHEMA fertiliser factory, Lithuania.

2003/04

Preparation of study on behalf of HRL (British Gas) on equipment maintenance and manning levels on the central production complex CPC1 (with main compression modules) and 5 further remote platforms DP3/4/6/8 and Calder – not normally manned in the South Field together with the North Field production and drilling platforms comprising the Morecambe Bay development with a capacity of 60 million cubic metres of gas per day (15% of UK peak gas demand).

2004

Team leader of a survey to review the technical and financial performance of the Cyprus Refinery Ltd on behalf or a potential purchaser. Work included environmental assessment including evaluation of water treatment and effluent treatment facilities.

2000/03

Preparation of basic design and international bid documents, including preparation of detailed capital and operating estimates, for $300 million extension to the Mugher cement plant, Ethiopia. Work included environmental assessment including evaluation of water treatment and effluent treatment facilities.
Client: The Government of Ethiopia.

2003

Preparation of capital and operating cost estimates on behalf of BP for the future phases of developments in Azerbaijan in the Shah Deniz gas liquids (LPG and NGL) cryogenic separation and storage facilities.

2001

Team leader for the preparation of feasibility study, including capital and operating cost estimates, into a 300,000 tonnes per annum polypropylene plant in Saudi Arabia on behalf of the Kannoo Group, Bahrain. Work included environmental assessment including evaluation of water treatment and effluent treatment facilities.

1998-2000

Undertook design audit and subsequent negotiations with contractors, reviewed international forms of model contract and advised on program schedules and cost estimates for ACHEMA fertiliser plant Lithuania – $100M extension requiring two new main air compressors and air separation plant and new ammonia storage tank.
 Client: The European Bank for Reconstruction and Development (EBRD).

1998

Carried out full technical and financial audit of the NAFCON plant at Port Harcourt on behalf of the NAFCON Executive Management Team and potential external investors. Carried out in-depth site audit of financial controls and production efficiencies with recommendations for plant modifications to improve efficiencies. Conducted in-depth discussions with Kellogg who were the local management contractor.

1998

Prepared basic design, project cost estimates, international bid documents (FIDIC orange book) and negotiated with contractors for the turnkey build of a $60 million glass bottle factory in Eritrea. Work included environmental assessment including evaluation of water treatment and effluent treatment facilities.

1995/96

Analysed process operating problems with the cryogenic turbo expander modules at Total St Fergus Gas Separation Plant. The work included review of operation of cryogenic turbo expander for gas liquid separation Identified problems arising from not operating in dense phase in offshore incoming pipeline and the resultant lack of LPG and NGL cuts available for sale.

1995/96

Project manager for the contractor on the turnkey design, procurement, construction and commissioning of $50M cotton ginning factory in Mali West Africa. Carried out all detailed design and procurement from Manderstam office. Work included environmental assessment including evaluation of water treatment and effluent treatment facilities.
Client: Wallace O’Connor 
Engineers and Contractors.

1994/95

Project manager for EPC turnkey, design, purchase, construction and commissioning of extension to styrene monomer storage facilities including contractor supervision at Huntsman, Manchester. Manderstam acted as main contractor and performed all basic and detailed design, procurement, logistics, site supervision and commissioning of works.

1992/94

Project manager (on behalf of the owner) of new vegetable oil refinery in Damman, Saudi Arabia including client liaison, cost control, design approvals and site supervision of contractor during construction and commissioning.

1991/94

Team leader on feasibility studies into port access and loading jetty layouts for urea storage, transfer and ship loading on behalf of GPIC. Subsequently carried out on behalf of GPIC the conceptual design, bid documentation and project management support services for the new Urea plant constructed by a Japanese contractor.

1991/92

Project manager (on behalf of the contractor) for detailed design, procurement, construction and commissioning of 20km NB offshore wet sour gas pipeline and onshore gas treatment and storage facilities (including the design of water treatment and effluent treatment facilities) in Qatar to BP Standards and Codes of Practice.

1991

Carried out HAZOP study on behalf of Exxon Mobil at the Fawley refinery.

1981/1991

Project manager/ design engineer for the following projects which included writing the contractor bid documents, mechanical specifications, procurement and site supervision or construction and commissioning for the following projects,:-

  • Mods and revamp to LPG/NGL loading jetty at LPG/NGL plant. Messaid including review and specification of cryogenic insulation for jetty pipelines and loading arms
  • Specified, purchased and commissioned reverse osmosis water treatment unit.
  • New gas booster compressor at LPG/NGL plant in Qatar. .
  • Wet sour gas pipeline pig launching/receiving plant in Qatar.
  • Offshore/onshore 24″ gas and 12″ liquid pipelines, 4″ NGL condensate pipeline
  • Redesign of oil storage tank farm and the specification and procurement of two new crude oil storage tanks.

Other projects included:

  • Process evaluation of C3 recovery scheme at NGL plant;
  • Diagnosis of crude oil loading pump problems in Qatar (requiring special investigation into the behaviour of dissolved gases in crude oil). -;
  • Evaluation of various design aspects of water re- injection scheme including Pipenet simulations and choke evaluations for rejecting water in depleted gas fields,
  • Design and specification of two new wet sour gas dehydration units, firewater system for NGL plant, and new sour gas well head treatment plants.

Manufacturing Industries

Examples of Relevant Operational Plant Design and Equipment:-

2018/19

Technical review of facilities including use of CHP steam and power generation at the soda ash plant, Nantwich on behalf of Tata Chemicals Europe Ltd.

2018/19

Prepared engineering expert advice on coolant/lubricant emissions and designing use of total enclosures during CNC machining of aluminium and steel products following HSE improvement notices.

2012/14

Prepared expert report on the design and operation of a chemical etching line for automobile aluminium castings on behalf of Electromechanical Supplies Ltd following a fire at Howmet Ltd.

2012

Prepared expert report on pneumatic hoist which fell leading to personal injury to operative.

2010/12

Prepared expert report and gave evidence on the failure of an access platform in boatyard leading to personal injury.

2012

Prepared expert report on high-pressure screed pump which failed, causing personal injury to operative.

2008/10

Prepared expert report on the design and manufacture of level switch in respect to its alleged failure, leading to the explosion at the Buncefield terminal in December 2005 and the major claim.

2008/09

Prepared expert report of a high-speed aluminium rolling mill and investigated damage arising out of the fire arising from the rolling oil/water lubricant.

2008

Prepared expert report on the quality of manufacture and fitness for purpose of stainless steel Jaguar fuel tanks in respect to a claim against the stainless steel supplier. Investigated failures of deep drawing process undertaking FMEA (failure mode and effects analysis) and compliance with ISO 9002 procedures.

2004

Prepared single joint expert report the following inspection and testing of a Wetrok floor cleaning machine and door mat at the entrance to a supermarket.

2002

Prepared expert report following inspection and testing of a swing door and door closing mechanism at the main entrance to the Tanbridge House School, Horsham.

2012

Prepared expert report on high-pressure screed pump which failed, causing personal injury to operative.

Examples Of Other Recent Experience In Quality Control and Manufacturing Systems:-

  1. Investigated design and material non-compliances in design and supply of 100 ball valves (6 inch through 20 inch ) for four (total 1400 MW) HRSG steam boilers (steam pressure 104 bar, temperature 565° C) dual fuel natural gas/fuel oil supplied for the Dubai Electricity and Water Authority Power and Desalination Station (phases I and 2). Work included FMEA (failure mode and effects analysis) and compliance with ISO 9002 procedures of non-destructive testing of castings for valve bodies.. 
  2. Reviewed valve and piping specifications and insulation specifications for cryogenic pipe work at South Hook LNG terminal on behalf of CB&I John Brown.
  3. Undertook review of Glaxo SmithKline Beecham’s piping standards in regard to material compatibility and corrosion in respect to 122 fluids in contact with carbon steels, stainless steels and plastics.
  4. Review and advice on a Gasholder designed to API620 /BS14015 for a major steel mill in Brazil on behalf of Ferrostaal, Essen, Germany.
  5. Undertook plant condition survey and prepared valuation of electroplating plant in Kosovo on behalf the Kosovo Trust Agency.
  6. Consultancy advice on high pressure steam piping construction and commissioning at a Biomass CHP power plant on behalf of RWE, Germany
  7. Prepared manufacturing profiles, including comprehensive quality control requirements, tooling specifications on the following manufacturing processes on behalf of United Nations Industrial Development Organisation (UNIDO):-
      • Rubber hoses for automotive replacement markets
      • V Belts for automotive replacement markets
      • Vehicle battery recycling
      • Melamine formaldehyde plastic laminates including production moulds
      • Light aluminium extrusions
      • PVC sheeting
  1. Prepared feasibility study for the production of cement products and ceramic tiles for the building industry on behalf of the government of Eritrea.
  2. Prepared feasibility study for plastic injection moulding including provision of all production moulds on behalf of the EBRD in Kosovo. 
  3. Car automobile scrap reclamation using electrolytic reclamation, Saudi Arabia – Basic Design and project management. 
  4. Technical audit of coating systems for washing machine manufacture in Dalian, China 
  5. Technical audit of Sheet Metalwork at Datine Mercantile Limited, Nairobi, Kenya on behalf of the Development Finance Corporation, London.
  6. Aluminium Smelting Plant, Ghana – Design and Execution
  7. Steel Production – Electric Arc, Nigeria – Design and project management
  8. Technical audit of the production of small electric motors, China.
  9. Technical audit of the production automobile batteries, Egypt.
  10. Technical audit of the manufacture of PVC Sheeting and Coatings at Sera Coatings Limited, Nairobi, Kenya.
  11. Technical audit of the production of cardboard packaging machines at Bucklips Packaging Limited, Aura, Ghana.
  12. Technical audit of the manufacture of latex rubber gloves at Tulip Industries Limited, Abidjan, Cote d’Ivoire.
  13. Upgrading PVC manufacturing plant to meet export requirements – ALCHIM – Romania.
  14. Technical audit of steel pipe manufacture, Shoudu, China
  15. Prepared manufacturing profile for the production of plastic pipe and fittings in Abu Dhabi on behalf of UAE Government.
  16. Prepared manufacturing profile for the production of plastic pipe and fittings in Eritrea, East Africa on behalf of the Government of Eritrea.
  17. Expensive metal processing at Sichuan, China
  18. Nd-Fe-P alloy production at Bantou, China

Plant & Equipment

Recent Experience In Machinery Equipment and Plant Valuation:-

2018

Prepared expert report and gave evidence at ICC hearing in Paris on valuation of process equipment in the manufacture of seamless pipe for the chemical industries.

2017

Valuation of over 100 variation claims on behalf of the JGCS Consortium, in respect to the NSRP new refinery in Vietnam.

2015/17

Carried out site survey, review of design and construction records and prepared expert report on design defects, delay and valuation of a new pharmaceutical plant in Kent UK.

2014/15

Prepared expert report and quantum analysis on 3-D piping design and stress analysis work on a topside skid in the North Sea.

2013/14

Instructed by the International Court of Arbitration to give independent expert opinion and gave evidence to the Tribunal in respect to quantum and valuation on process and mechanical engineering issues at an LDPE plant in Germany.

2011/13

Prepared quantum and valuation report of like-for-like replacement of the machinery regarding Owners claims for rebuilding one of the largest confectionery factories in UK following a major fire.

2011/12

Prepared expert reports and gave evidence at the International Court of Arbitration on EPC project cost estimates and valuation of design and construction changes in respect to a nitric acid and ammonium nitrate plant in the Middle East.

2008/09

Prepared expert report on quantum and valuation of a high- speed aluminium rolling mill and investigated damage arising out of fire that occurred during rolling.

2008/10

Preparation of the basic design, including preparation of basic specifications for all packaging equipment for a 20,000 tonnes per annum citric acid plant in Saudi Arabia.

2005

Undertook plant and equipment valuations at 24 manufacturing companies in Kosovo on the behalf of the EU in preparation for large-scale privatisation tenders. Companies range from hot and cold strip mills, fabrication shops, plastic injection moulding companies, anodising and finishing plants, machine shops to flour mills and food processing companies.

2005

Preparation of valuation of cement process plant in Sudan on behalf PKF accountants.

2000/03

Preparation of basic design and international bid documents, including preparation of detailed capital and operating estimates, for $300 million extension to the Mugher cement plant, Ethiopia. Work included environmental assessment including evaluation of water treatment and effluent treatment facilities.
Client: The Government of Ethiopia.

2003

Preparation of capital and operating cost estimates on behalf of BP for the future phases of developments in Azerbaijan in the Shah Deniz gas liquids (LPG and NGL) cryogenic separation and storage facilities.

2001

Team leader for the preparation of feasibility study, including capital and operating cost estimates, into a 300,000 tonnes per annum polypropylene plant in Saudi Arabia on behalf of the Kannoo Group, Bahrain. Work included environmental assessment including evaluation of water treatment and effluent treatment facilities.

1998/2000

Undertook design audit and subsequent negotiations with contractors, reviewed international forms of model contract and advised on program schedules and cost estimates for ACHEMA fertiliser plant Lithuania – $100M extension requiring two new main air compressors and air separation plant and new ammonia storage tank- Client The European Bank for Reconstruction and Development (EBRD).

1998

Carried out full technical and financial audit of the NAFCON plant at Port Harcourt on behalf of the NAFCON Executive Management Team and potential external investors. Carried out in-depth site audit of financial controls and production efficiencies with recommendations for plant modifications to improve efficiencies. Conducted in-depth discussions with Kellogg who were the local management contractor.

1998

Prepared basic design, project cost estimates, international bid documents (FIDIC orange book) and negotiated with contractors for the turnkey build of a $60 million glass bottle factory in Eritrea. Work included environmental assessment including evaluation of water treatment and effluent treatment facilities.

Food Industries

Examples of Relevant Plant Design and Equipment in the Food Industries:-

2019/20

Prepared expert report and gave evidence on the mechanical design of pasteurising tanks and heaters and a waste to biogas plant in UK.

2019

Prepared expert report as an expert adviser on the design of an enzyme production plant in UK.

2018/19

Technical review of facilities including use of CHP steam and power generation at the soda ash plant, Nantwich on behalf of Tata Chemicals Europe Ltd.

2013/14

Prepared quantum and valuation report of like-for-like replacement of the machinery regarding Owners claims for £63 million for rebuilding one of the largest confectionery factories in UK following a major fire.

2008/10

Preparation of the basic design, including preparation of basic specifications for all packaging equipment for a 20,000 tonnes per annum citric acid plant in Saudi Arabia.

2007

Prepared expert report and gave evidence on the quality of manufacture and fitness for purpose in respect to a claim from the purchaser against a manufacturer of a potato harvester.

2005

Undertook plant and equipment valuations at 24 manufacturing companies in Kosovo on the behalf of the EU in preparation for large-scale privatisation tenders. Companies range from hot and cold strip mills, fabrication shops, plastic injection moulding companies, anodising and finishing plants, machine shops to flour mills and food processing companies.

2002

Preparation of reports on soya bean crushing equipment in Saudi Arabia.

1998/99

Project Director – Techno-economic and pre-investment study for the Eritrean government on the potential of table salt sector to be modernised to meet projected domestic demand and be able to penetrate world markets project including the specification of all packaging machinery equipment.

1997

Prepared technical report on the processing and packaging machinery of date dibis (i.e. date syrup) and date honey.

1996

Prepared technical Studies on the machinery for the sterilisation and bottling of Sparkling Mineral Water.

1995

Prepared technical specifications for the machinery for packaging tomato paste and citrus fruits in Zimbabwe.

1993

Preparation of specifications for the machinery for packaging of margarine and ice-cream in Saudi Arabia

1993

Project management of new $50M vegetable oil refinery in Damman, Saudi Arabia including design approvals and site supervision for machinery for a vegetable oil bottling line.

1992/93

Slovakia and Hungary- Potato processing and agricultural plant micropropagation including the specification all packaging machinery equipment

1992

Technical, market and economic feasibility study of an industrial scale penicillin plant in the Philippines, including packaging machinery equipment for capsules and tablets.

1991

Technical, market and economic feasibility study of a multi-purpose chemical synthesis plant in the Philippines including packaging machinery equipment for capsules and tablets.

1988/90

Technical, economic and market feasibility studies on behalf of the World Bank.

  • Techno-economic Feasibility Study on Proposed Expansion of a Vegetable Oil and Soap Plant at Appiah-Menka Complex Limited, Ghana.
  • Techno-economic Feasibility Study on Pharmaceutical Manufacturing Plant for Intravenous Infusion Solutions and Automatic Packaging Systems at Oron, Akwa and Ibom State, Nigeria.
  • Paper Packaging at Highland Paper Mills, Eldoret, Kenya.
  • Pharmaceuticals at Pharmivoire Limited, Abidjan, Cote d’Ivoire.
  • Cardboard Packaging at Bucklips Packaging Limited, Aura, Ghana.
  • Latex Rubber Gloves and packaging at Tulip Industries Limited, Abidjan, Cote d’Ivoire.
Other Food Processing:-

1992/93

Slovakia – Agricultural micropropagation unit for potatoes.

1991/92

Poland Single cell protein production of animal feeds.

1992

Saudi Arabia – Food presentation.

1991/92

Poland – Single cell protein production.

1991/93

Ireland – Single cell protein production.

1990

Ghana – Vegetable oil processing.

1989

Ghana – Jute processing.

1989

China – Citric acid and lactic acid production.

1989

China – Flax processing

1989

China – Enzyme production
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