Success stories and recent technical cases

IPS Engineering has supported industrial companies in the management of technical projects, plant assessments, process optimization, interventions on existing plants, and project management activities.

The cases presented are selected examples of engagements in which IPS helped clarify the technical issue, evaluate alternatives, manage interfaces, and support more robust, well-documented operational decisions.

New ATB loading canopies - San Marco Petroli fuel depot

IPS Engineering initially carried out a technical feasibility assessment of the design solution proposed by a third-party engineering company. Following this analysis, IPS was directly appointed by the client to review and develop a new design solution, as well as to provide the technical support required for the construction of the new loading canopies at the San Marco Petroli depot.

The scope of work included the civil and structural design of the facility and the development of the multidisciplinary design of the plant interconnections between the loading skids, the additive injection skids, the pump room, and the vapor recovery unit (VRU), with particular attention to interfaces, operational safety, and the functional consistency of the overall system.

IPS’s contribution focused on rationalizing the technical solutions, managing the interfaces between the different systems, and verifying design consistency against operational and regulatory requirements, ensuring a technically sound and sustainable implementation.

The project is an example of senior engineering applied to small and medium-sized industrial plants, where added value was delivered through technical governance, multidisciplinary integration, and solution optimization, while maintaining an effective balance between technical requirements, schedule, and costs.

Tank mixing optimization

The optimization was achieved by replacing air injection with Venturi-effect mixing nozzles, making use of the existing extraction pumps to ensure effective circulation of the liquid in the tank. This modification reduced the mixing time from 12 to 2 hours and eliminated the environmental impact caused by fugitive emissions from air injection.

Alternative to mechanical agitator in ATEX area

After careful analysis of the available options, we proposed an alternative to the mechanical agitator that proved highly effective. Using the extraction pump, we implemented bottom-up agitation of the liquid through a mixing nozzle, completely eliminating settling and reducing energy consumption compared to the mechanical agitator, resulting in cost savings for the client.

Fluid dynamics simulation for investment assessment

The initial idea was to build a canopy to protect the chemical storage tanks from direct solar radiation. The simulation results showed that, even under the most unfavorable weather conditions, the temperature of the liquid in the tank did not exceed 53°C. Based on these results, it was decided to abandon the plan to build the canopy, since the critical safety threshold was not reached.

Technical database for tank management

IPS has successfully implemented a custom database for the efficient management and maintenance of storage tanks. The system provides detailed traceability, automated maintenance scheduling, and real-time notifications, improving safety and operational efficiency.

P&ID digitalization and 3D plant model

IPS carried out the digitalization process starting from the existing P&IDs, ensuring consistency with the actual field conditions. In parallel, alongside the modification projects, it developed a 3D (BIM) model of the plant, significantly improving data management and understanding of the infrastructure.

Aerial crossing of hazardous product piping

IPS was consulted to address the issue of operational safety in the transfer of hazardous products through underground pipelines crossing a public road. The crossing, originally built in the 1960s, no longer complies with current, more stringent regulations and cannot be modified due to the surrounding underground utilities. After a careful analysis of the problem, IPS proposed an arched overhead pipe bridge solution, characterized by simplicity, elegance, and cost-effectiveness compared to the other available options.

Project management and construction supervision

For the seismic retrofitting and modernization project of an industrial site, IPS was appointed to carry out project management and construction supervision activities. The IPS team dealt with daily challenges related to resolving unforeseen issues, monitoring project progress, and managing safety and resources, successfully overcoming these obstacles.

Batch to semi-continuous conversion

For a client owning an ethyl acetate production plant, IPS managed the modernization process by converting the existing plant from batch to semi-continuous operation in order to increase production. The revamping project involved introducing reactive distillation into the existing plant.

DO YOU HAVE A TECHNICAL CASE TO ASSESS?

IPS can support you with the preliminary review of the issue, the evaluation of alternatives, and the definition of the most suitable technical approach.