The Challenge
The client needed to feed a new slurry Chrome Catalyst injection system into an existing 400 KTPA Polyethylene Loop Reactor. To sanction the project, they needed a complete FEL-2 (Basic Engineering) package — design basis, cost estimate accurate to ±30%, and schedule — developed quickly enough to keep the broader capital project on track, without diverting their own senior engineering staff from other priorities.
What We Did
Rosnik fielded a mixed US–India team, with the US side largely staffed by engineers with prior ExxonMobil experience, to deliver a full basic engineering scope:
- US team: Technology lead, piping, partial procurement support, and cost estimating
- India team: Process, civil, electrical, instrumentation, and partial procurement support
Deliverables included:
- Issued-for-Design PFDs, material balance, pump and piping size verification
- Preliminary P&IDs, redlined plot plan (equipment locations), routing schematic, line list, tie-in list, equipment data sheets
- Equipment list, major equipment quotes, electrical cabinet locations and breaker sizing, instrument list
- Total Installed Cost (TIC) estimate to ±30% or better, and project schedule
The Outcome
The full FEL-2 basic engineering package was delivered on schedule in 10 weeks, giving the client everything needed to sanction a ~$10M project — for an engineering cost of $65K.
Why It Worked
Splitting technology and client-facing leadership (US, ex-ExxonMobil engineers) from detailed multi-discipline execution (India-based process, civil, electrical, and instrumentation teams) let Rosnik move fast without compromising technical rigor — delivering a sanction-ready package at a fraction of the cost typically associated with FEL-2 studies of this scope.
Value Creation
A $65K FEL-2 package unlocked sanction-readiness for a $10M capital project — roughly 0.65% of TIC, well below typical FEL-2 cost benchmarks for this scope.