Plant Design Summary

We

Process & Plant Design

Don’t Panic

Just calm down

You are a Chemical

Engineer

6

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

7

Defining the Project

Statement of Work– Project Purpose– Project Scope – Deliverables– Cost & Time Schedule Estimates– Ownership and Authority

8

What are the Resources to Manage?

Equipment

MaterialsPeople Money

Time

9

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

22

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?