MFE - James D. Madden, P.E.'s Engineering Design Experience
  Examples of Systems Designed and Specified
                        while Employed in Industrial Operations and Design Engineering 
  • Overpressure relief systems
  Examples of Facilities Designed while Employed in Industrial Operations and Design Engineering
Safety Design of Equipment and Facilities - including safeguards and warnings
Safety design was a routine, integral part of the engineering design of all industrial and manufacturing equipment and facilities while employed in industrial operations and engineering design.
Air and Water Pollution Control Facilities
  • Gas vent stacks for numerous industrial and manufacturing facilities.
  • Water pollution control design for an acrylonitrile manufacturing.
  • Water pollution control facility for a high density polyethylene manufacturing facility.
Utility System Facilities  (steam, treated water, plant and instrument air, nitrogen, etc.)
  • a petrochemical, utilities and storage complex, a large group of industrial, manufacturing, utilities and storage facilities
  • a lube oil manufacturing facility
  • a substitute natural gas (SNG) manufacturing and storage facility.
  • a pharmaceutical manufacturing facility.
  • a polystyrene manufacturing facility.
Industrial and Manufacturing Facilities
  • Plastics manufacturing grassroots* facilities including:
  • low density polyethylene manufacturing facilities
  • polypropylene manufacturing facilities
  • a polystyrene (styrene) manufacturing facility
  • extrusion and compounding facilities (used to knead plastics) for grassroots high density polyethylene manufacturing facilities
  • Petroleum processing facilities including:
  • a lube oil manufacturing facility
  • a crude oil topping facility
  • a naphtha reforming (reformulation) facility
  • a gas oil separation facility with stabilization
  • Chemical production grassroots* facilities including:
  • herbicide manufacturing facilities
  • ethyl hexanol manufacturing facilities
  • a MTBE and paraxylene absorption manufacturing facility
  • a MTBE and Dimersol manufacturing facility
  • a benzene hydrofining unit
  • a fire retardant manufacturing facility
* "grassroots" facilities, also known as "greenfield" facilities are facilities which are totally new, starting
    with the grading of the groundsuch facilities may or may not be in a manufacturing complex with
    other older completed facilities
  • Natural gas processing grassroots* facilities including:
  • a natural gas processing facility and export terminal
  • an underground peak shaving natural gas storage facility
  • a natural gas saturates facility
  • a natural gas and hydrocarbon liquids processing facility.
  • Renovation of solvent recovery and refining facilities for a high density polyethylene manufacturing facility
  • Dry ice expanded tobacco manufacturing facility.
  • a natural gas separation facility
  • a natural gasoline facility.
  • Tank farms (a large number of large tanks and associated equipment, piping and instrumentation in a stand-alone facility) for:
  • a facility for revaporization of liquefied natural gas
  • a facility to produce substitute natural gas (SNG).
  • Downsizing and modernization of:
Other Technical Activities Associated with Engineering Design
  • Conducted equipment operation testing in manufacturing facilities

  • Performed industrial operation studies in manufacturing facilities, including studies to develop the data required to design additional similar facilities

  • Performed drainage studies in industrial and manufacturing facilities to develop the data required for the design of surface facilities and trenches/flumes and sewers for the drainage required

  • Designed specialized safety and air pollution control systems, including flares, vents, foam fire protection systems and the like

  • Assisted with construction of industrial and manufacturing facilities, including providing technical assistance to Construction personnel at the construction site and providing construction site engineering design services and supervision of construction


  • Participated in the commissioning (completing the construction) and startup of manufacturing facilities

  • Designed and presented courses to Design Engineers covering the design of safety relief devices and safety relief systems

  • Organized, participated in and supervised the writing of Design Manuals for equipment, machinery, piping, valving and instrumentation to meet safety design requirements and applicable codes, standards and recommended practices

  • Organized, participated in and supervised the writing of a Design Manual for the design of boiler systems to meet safety design requirements and the ASME Boiler Code and other applicable codes and standards

  • Assured the technical quality of engineering designs, especially of the safety design of equipment and facilities, design of safety facilities and  warnings; through hands-on reviews and formal technical reviews and approvals of engineering designs of industrial and manufacturing facilities, piping, valving, instrumentation, equipment and machinery

  • Made use of industry, technical society and government codes, standards and recommended practices extensively during design of industrial and manufacturing facilities, piping, valving, instrumentation equipment and machinery, and advised and instructed others on the proper use of these Codes in their design
  • Pressure relief systems for numerous industrial and manufacturing facilities.
  • Gas and liquid burning flare stacks for numerous industrial and manufacturing facilities.
  • Fire suppressant systems, including water, inert gas and foam systems for several facilities.
Specialized Safety Facilities, including those using fire and those for fire suppression
  • designing equipment to reduce or eliminate hazards in the use of the equipment, which is usually called designing out the safety hazards
  • the specification of safeguards (such as barrier guards, light curtains, dual operating buttons, safety instrumentation, etc.) as required
  • the designing or specification of warnings as required
  • Human Factors and the analysis of the human - equipment and human - facility interfaces
  • accepted engineering safety standards and practices
  • Codes & Standards and Recommended Practices
 
  • first, design out the safety hazards in equipment, products and facilities whenever possible
  • second, use safeguards to protect from those safety hazards which cannot be designed out
  • third, use warnings for those safety hazards which cannot be designed out and for which safeguards cannot be used to protect from the safety hazard
  • fourth, use warnings to complement safeguards when safeguards are used to protect from hazards
  Safety design includes:
  Safety design is based on:
  • do NOT use warnings in place of safeguards or designing out a hazard, if these are practical
  • do NOT use safeguards in place of designing out a hazard, if this is practical
  Design using the Safety Design Hierarchy has prohibitions as follows:
  • Control system panel layouts • alarm panel layouts
  • Fire suppression systems
  Examples of Engineering Design Activities
      while Employed in Industrial Operations and Design Engineering
MAAFE
Madden
Accident
Analysis & 
Forensic
Engineering
MAAFE
Phone: (440) 838-1191
Phone: (440) 838-1191
  • automatic and manual control systems
  • local and remote control systems
  • pneumatic, electrical and hydraulic control systems
  • including those specifically designed to assure the safety of the operation of equipment and systems
  • including the associated piping, valves, equipment and instrumentation
  • Hazardous chemical (liquid and gas) relief systems
  • Air pollution systems
  • including the associated piping, valves, equipment and instrumentation
  • Surface and open subsurface drainage and spill containment systems
  • including the associated piping, valves, equipment and instrumentation
  • Gravity and pressure industrial sewer systems
  • Liquid and solid industrial waste disposal facilities
  • including the grading, surfacing, trenches and flumes
  • Control systems including:  
  • including skimmers, and flotation and settling clarifiers
  • Steam and electricity co-generation systems (which generate steam and electricity at the same time)
  • Refrigeration systems
  • including water, foam and inert gas systems
  • Utility production systems for the production of:
  • including machinery (compressors, etc.), controls, safety systems and piping
  • Utility distribution systems
  • steam (using boilers)
  • treated water for industrial purposes
  • plant and instrument air
  • nitrogen, etc.
  • Signage, including warning signs
  • Equipment and machinery layouts
  • building and structure specifications
  • including piping, instrumentation and controls
  • Utility distribution systems for numerous industrial and manufacturing facilities
  • including piping, instrumentation and controls
  • Utility production systems for the production of:
  • steam (using boilers)
  • treated water for industrial purposes
  • plant and instrument air
  • nitrogen, etc.
for use in:
Safety design is performed based on the the Safety Design Hierarchy, which is the accepted system for design of safe equipment, systems, products and facilities. The Safety Design Hierarchy requires designing for safety as follows:
Engineering Design Activities - Table of Contents - links to content on this page
 
Engineering Design Details - Table of Contents - links to content on this page
The examples of details of engineering design listed below are provided for the convenience of the user of this webpage in finding particular subjects. They are not all-inclusive, and also omit the subjects with links provided on the Table of Contents immediately above. Thus, if you are looking for particular equipment, facilities, design subject, etc., you may find scrolling through the complete page contents or using Ctrl-F (Page Search) to be more useful in this search.
Additional Activities while working in
Engineering Design:
*
**
Examples of Specialized Design Activities:
Examples of Details of Facilities Designed:
EEngineering Design, Other Engineering Activities, and Equipment and Facilities Designed by James D. Madden, P.E. While Employed in Industrial Operations and Design Engineering
Copyright 2011, 2012, 2015, 2016, 2018 by Madden Accident Analysis & Forensic Engineering and James D. Madden, aka James Madden and Jim Madden. All rights reserved. This website contains photographs which are licensed with restrictions that prohibit downloading, reproduction, re-publication or re-transmission.
Madden Accident Analysis & Forensic Engineering, through its Senior Forensic Engineer, James D. Madden, P.E., a licensed professional engineer, has performed Accident Investigations, Engineering Analyses and Accident Reconstructions routinely for accidents, incidents and cases located in Ohio, Pennsylvania, Michigan, and New York, in the technical areas which are noted in this website, as well as providing expert reports and testifying in court proceedings in these states in the capacity of an Expert Witness, including depositions, arbitrations and/or trials, with Forensic Engineering work also performed in, and/or for cases in, Illinois, Maryland, North Carolina, Vermont, Kansas and Utah.
Madden Accident Analysis & Forensic Engineering, through its Senior Forensic Engineer, James D. Madden, P.E., a licensed professional engineer, has performed Accident Investigations, Engineering Analyses and Accident Reconstructions for accidents, incidents and cases in the metropolitan areas of Cleveland, Akron, Canton, Toledo, Warren, Youngstown, Mansfield, Columbus, Dayton, Cincinnati, Lima, Findlay, Marietta and Steubenville, as well elsewhere throughout Ohio, and the metropolitan areas of Pittsburgh and Erie, as well as elsewhere throughout western and central Pennsylvania, and the metropolitan areas of Detroit, Ann Arbor, Lansing, Flint and Port Huron, as well as elsewhere in southern Michigan, and the metropolitan areas of Buffalo and Syracuse, as well as elsewhere in western and central New York state. In many of these areas James D. Madden, P.E. has provided expert reports and testified in the capacity of an Expert Witness in court proceedings, including depositions, arbitrations and/or trials
Madden Accident Analysis & Forensic Engineering, through its Senior Forensic Engineer James D. Madden, P.E., is available for Accident Investigations, Engineering Analyses, Accident Reconstructions, and testimony in deposition, arbitration and trial, for cases located throughout North America.
Madden Accident Analysis & Forensic Engineering
These Systems were designed using Safety Design and Human Factors principles, conformed to applicable Codes & Standards, and included Safeguards and Warnings where required
These Facilities were designed using Safety Design and Human Factors principles, conformed
to applicable Codes & Standards, and included Safeguards and Warnings where required
  Examples of Equipment and Components Designed and Specified
                        while Employed in Industrial Operations and Design Engineering
  • Safety and overpressure relief valves • rupture discs
  • overpressure blowout panels
  • Skimmers, flotation and settling clarifiers
  • Ground flares and elevated flare stacks for burning hazardous gases and liquid chemicals
  • Non-burning vent stacks for disposal of non-hazardous gases to meet EPA anti-pollution regulations
  • Gas blowers • fans
  • Ejectors
  • Compressors (for gases, including air and nitrogen) including:
  • Piping and tubing ranging from approximately 1/4 inch to 48 inches in diameter, used for:
  • water
  • steam
  • gases
  • chemicals
  • pneumatic control and power systems (using air or nitrogen)
  • hydraulic control and power systems  (using hydraulic fluid), etc.
  • Valves ranging from approximately 1/4 inch to 48 inches in size including:
  • hand-operated valves
  • remote-operated valves (with electrical, hydraulic or pneumatic control and power)
  • automatically operated valves (with electrical, hydraulic or pneumatic control and power)
  • gate valves
  • globe valves
  • needle valves
  • butterfly valves
  • ball valves
  • rotary valves, etc.
  • Furnaces, including:
  • centrifugal compressors
  • reciprocating compressors
  • screw compressors
  • Pumps (for liquids, including water and chemicals) including:
  • centrifugal pumps
  • reciprocating positive displacement pumps
  • screw positive displacement pumps
  • sump pumps, etc.
  • Vacuum pumps (for gases - creates and maintains a vacuum)
  • Turbines, motors, and engines to drive machinery, including:
  • steam-driven turbines
  • gas-expansion turbines
  • electric motors
  • gas-fired and oil-fueled engines
  • compressors
  • pumps
  • blowers,
  • conveyors
  • plastics processing equipment
  • similar powered equipment
machinery driven by turbines, motors, and engines includes:
  • Heaters and heat exchangers including:
  • safety, control, fuel, exhaust and product instrumentation systems
  • piping and ductwork systems
  • Dryers for solids, including:
  • liquid to liquid heat exchangers
  • liquid to gas* heat exchangers
  • gas* to gas* heat exchangers
  • shell and tube heat exchangers
  • double pipe heat exchangers
  • multipipe heat exchangers
  • plate heat exchangers
  • bayonet heat exchangers
  • air coolers
  • tank coils
  • vessel jacketing
  • kettle reboilers
  • thermo-siphon reboilers
  • vessel and tank heaters, etc.                             
  • Direct-fired boilers • waste-heat boilers (including steam generators), including:
  • safety, control, fuel, exhaust and product instrumentation systems
  • piping and ductwork systems
* gases handled by heat exchangers included air
  • Dehumidifiers to remove liquids from gases
  • Pressure and vacuum vessels and tanks for liquids and gases.
  • Atmospheric storage tanks for liquids
  • Storage bins for solids and particulates
  • Distillation, absorption and solvent extraction columns, including:
  • rotary dryers
  • fluidized bed dryers
  • spray dryers, etc.
  • Plastics processing equipment, including:
  • trayed and packed columns.
  • Conveyors, including:
  • compounders
  • extruders
  • choppers, etc.
  • Liquid and gas filters and bag houses
  • belt conveyors
  • pneumatic conveyors
  • screw conveyors
  • bucket conveyors, etc.
  • impingement separators
  • cyclone separators, etc.
  • Traveling cranes, traveling winches, etc.
  • Materials of construction for:
  • piping, equipment, machinery, etc.
This Equipment and these Components were designed using Safety Design and Human Factors principles, conformed to applicable Codes & Standards, and included Safeguards and Warnings where required
  • Separators, including:
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  Safety Design Activities
  Other Technical Activities
  Examples - Equipment Designed
  Examples - Systems Designed
  Examples - Facilities Designed
  Doing Safety System Designs
  Doing Designs Using Fire
  Doing Designs to Prevent & Fight Fire
  Presenting Safety Design Courses*
  Preparing Design Manuals**
  Assuring Safety Design
  Using Codes & Standards
  Specifying Signage
  Doing Facility & Equipment Layout
  Engineering Design Details
  Curriculum Vitae, CV, Resume' (center menu)
  Contact Information (center menu)
  List of Links to Other Pages (left sidebars)
  Equipment Operation & Testing
  Industrial Operations' Studies
  Construction Assistance
  Facilities Commissioning
  Facilities Startup
  Specialized Safety Facilities
  Pollution Control Facilities
  Utility Systems
  Manufacturing Facilities
     click on the underlined squares to link to the subject
See the Employment Page for details on specific employers and employment in Industrial Operations and Design Engineering
     click on the underlined squares to link to the subject
also designing these courses
writing sections & supervising writing by others
EEngineering Design, Other Engineering Activities, and Equipment and Facilities Designed by James D. Madden, P.E. While Employed in Industrial Operations and Design Engineering
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Madden Accident Analysis & Forensic Engineering
8803 Brecksville Road, Suite 7-216, Cleveland, Ohio 44141
1700 West Market Street, Suite 318, Akron, Ohio 44313
phone: 440-838-1191 or 440-832-9540, fax: 440-838-1192
email address: info@maddenforensic.com or info@maafe.com

over 30 Years Investigating, Analyzing, Reconstructing and Testifying about Accidents
Contact us for more information ▪ phone 440-838-1191 or 440-832-9540 ▪ info@maddenforensic.com