Post on 29-Mar-2015
Plant Design Summary
We
Process & Plant Design
Don’t Panic
Just calm down
You are a Chemical
Engineer
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What Is a Project?• A project is “a temporary endeavor undertaken to
accomplish a unique ( non-repetitive) product or service”
• Attributes of projects:– unique purpose– temporary– require resources, often from various areas– should have a primary sponsor and/or customer– involve uncertainty
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Defining the Project
Statement of Work– Project Purpose– Project Scope – Deliverables– Cost & Time Schedule Estimates– Ownership and Authority
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What are the Resources to Manage?
Equipment
MaterialsPeople Money
Time
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Project Management Framework
Design-bid-build contract
General conditionsSpecsBill of quantitiesDrawingsCM/CS
Design-bid-build Cont’d
• Owner– Consultant
Contractorconsultant
Contract goals :
Contract Types1. Fixed prices or lump sum contract
2. Reimbursable type
Fixed Price Contract:• Defined scope• The type used for supply of materials &
equipment• The red-book model
Reimbursable type:• Applicable when scope is not clearly defined• Contractor to be reimbursed for both direct and
indirect costs
Project time management involves the processes required to ensure timely completion of a project. Processes include:
– Activity definition– Activity sequencing – Activity duration estimating– Schedule development– Schedule control
Project Time Management Processes
Project schedules grow out of the basic document that initiates a project:
1. Project data includes start and end dates and
2. Budget information 3. Scope statement and WBS help define what
will be done Activity definition involves developing a
more detailed WBS and supporting explanations to understand all the work to be done so you can develop realistic duration estimates
Activity Definition
• Gantt or bar charts• Network analysis
– The arrow diagram– The precedence diagram– Critical path analysis– Techniques for shortening a project
schedule
TOOLS
Simple example (Project Planning…Gilland Chart):W10 W9 W8 W7 W6 W5 W4 W3 W2 W1 Activity
A1
A2
A3
A4
A5
• A series of activities plotted on a time-scale • Each activity has an assumed definite start, duration and end• Activities could be either related or independent• All activities must be complete before the total project is complete.• The level of detail could be enlarged or reduced.• The completion date could move backwards or forwards depending upon
intermediate results• Progress could be shown against each activity.• The plan could be reviewed from time to time to suit changed conditions.
FloatMay Apr Mar Feb Jan Activity
Review designs
May Apr Mar Feb Jan Activity
Review designs
Review designs
The term “float” implies that the activities have certain freedoms.Float time is not free time Responsibility
(a)
(b)
This activity:- Can not start before mid-Feb.- Must be completed by mid-April.- It will take about 4 weeks to complete.
1. An activity (successor) requires its (pre decessor) to be complete before it can start
2. Two activities must be complete before a successor can start. The two activities run in parallel
Basic types of time relationships:
A finish – to – start relationship
A finish – to – finish relationship
A start – to – start relationship
Resources on a bar chartWeek
4Week
3Week
2Week
1Activity
Excavate Foundation
Prepare driveway
Concrete found
Erect fencing
2 6 4 4 Labour, total
Resources required: Manpower (different types) Equipment Cash Subcontractors (different types)
2 2
2 2
4
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The plant-site relationship:
Variability in basic requirements :
Area requirements, m2
Water requirements, m3 /hr Utility requirements
Electrical powerTelephone Natural gasWaste disposal( gas, liquid, solid )
Special Labor requirements
N.B: Mention Clusters & 14 Factors (not constant)
Global Manufacturing Location Decision
Country FactorsFavorable economic, political, cultural conditions
Technological FactorsFixed costs relatively lowMinimum efficient scale
Scale of output a plant needs to realize scale-economiesMarket demand must be sufficient to reach this scale
Flexible manufacturing-lean production-mass customization
Product featuresValue-to-weight ratioUniversal needs
1. Information required to select a site
1.1 Maps and surveys
Maps Surveyssource surveying contractorscale benchmarkdate contours
The Egyptian Survey Authority
1. Information required to select a site
1.2 Topography, Terrain and soil properties• Topographical maps• Site terrain ( sand, rock , march) will influence
cost of construction• Soil investigations
– Soil investigation contractors– Soil investigation reporting
Magnitude of the problem (2)Industry-Environment P-S-R Model
Pressures on the Environment
Air pollution Water pollution Soil pollution
State of the environment and natural resources:
Local Regional National Global
Responses:
Government Society Industry
Regarding:
Existing plants New plants
Redundant Control System
Statement of the problem
Siting of chemical process plants
1. Two risk domains 2. Three layers of interaction
Industry internal
risk
Industry external
risk
Industry Society
Environment
The field of technological risk assessment
The field of land-use planningGAP
Definitions of Risk
The Seveso II Directive defines “risk” as follows:Risk: the likelihood of a specific effect occurring within a specified period or in specified circumstances
The definition according to ISO/IEC 51 reads:Risk: the combination of the frequency or probability of occurrence and the consequence of a specified hazardous event.
Risk Assessment:Risk Assessment: the overall process comprising a risk analysis (the systematic use of available information to identify hazards and to estimate the risk) and risk evaluation (procedure whether the desirable level of risk has been achieved)
Risk Management:Risk Management: Systematic application of management policies, procedures and practices to the tasks of analyzing, evaluating and controlling risks
Land use planning
“Land Use Planning” can be defined as “a systematic assessment of alternative patterns of land use and other physical, social and economic conditions, for the purpose of selecting a land-use option which is most beneficial to land users without degrading the resources or the environment..”
Land Use Planning has to be understood as an
aspect of “spatial planning”
Individual risk: --- Risk Contours
ISO-risk contours represent the geographical variation of the risk for a hypothetical individual who is positioned at a pacticular location for 24 hrs/day, 365 days / year.
LSIR: Location specific individual risk
General Factors in Planning Layouts:1. New site development vs. addition to a
previously developed site.2. Future expansion.3. Economic distribution of services – water,
steam, power, gas.4. Weather conditions, outdoor vs. indoor
construction.5. Safety considerations – possible hazard of fire,
explosion or fumes.6. Building code requirements.7. Waste Disposal Problems.8. Sensible use of Floor & Elevation Space.
Data Requirements for the preparation of a conceptual layout:
1. Equipment list with approximate dimensions.2. Process flow sheets or preliminary P & ID’s
showing relative elevations.3. Off-site requirements – buildings, tank farms,
diked areas,railroads, cooling towers, storage areas,
4. Hazard considerations.5. Process buildings and/or structure requirements
(open/closed).6. Future expansion considerations.
Atmospheric
Tankage
300 x 600 ft.
Low Hazard
Process Areas
600 x 500 ft.
Parking
Maintenance
Warehouse
200 x 600 ft.
Utilities
200 x 300 ft.
Flare
200 x 300 ft.Offices
200 x 200 ft.
200 ft.
NM
200 ft.
100 ft.
Spacing around flare based on radiant heat calculations
Spacing based on local building codes
Property Line
Total Land Area = 45 acres
1300 ft.
1500 ft.
NM
100 ft.
100 ft.
Typical layout assembly plan
CAD generated three dimensional models (Sub-process Area) :
Economic & Technical Factors in Chemical Plant Layout
% Cost brake down of major plants:
25 Major plant items, material cost
21 Buildings and structures
15 Pipework and valves
12 Development and design
5 Electrics
5 Instruments
5 Start-up
5 Construction charges
2 Land and site clearance
2 Auxiliaries
3 Miscellaneous (under 1% each)
100%
% where the Money Goes in Piping:
30 Fabrication
27 Valves
18 Hangers
9 Design
7 Erection
5 Tube
4 Flanges, bolts and joints
100%
Input data to Plot Plan
Important Equipments Mentioned
• Drum• Pumps• Reactors• Towers• Pipe Racks
N.B : Installation and Precautions
Why reliability?Operational Excellence is biggest profit contributor
Company Profit
OperationalExcellence
Reliability Excellence
Operational Excellence is biggest controllable contributor to sustainable profit.
Operational Excellence needs a reliable foundation: People Processes
Tools Metrics Mention KPI
ABB Confidential and Proprietary Information
Aberdeen’s MethodologyEnd-User Investigation: PACE Framework
P
A
C
E
Pressures:External and internal forces that impact an organization’s market position, competitiveness, or business operations.
Actions:The strategic approaches that an organization takes in response to industry pressures.
Capabilities:The business competencies (organization, process, etc…) required to execute corporate strategy.
Enablers:The key technology solutions required to support the organization’s business practices.
Decisions for Asset Lifecycle Management
32%
36%
41%
47%
52%
60%
64%
65%
81%
0% 25% 50% 75% 100%
Environment and energy management
Safety - Employee and Asset
Asset decommissioning
Asset commissioning
Training and certification
Asset repair / refurbish / overhaul
Spare parts management
New asset procurement
Asset reliability and maintenance
Survey Question: Please describe which of the following decisions you influence?