Plant Design Summary

1. Plant Design Summary

2. We Process & Plant Design

3. Don’t Panic

4. Just calm down 

5. 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? Money People Materials Time Equipment

9. Project Management Framework

11. Design-bid-build contract General conditions Specs Bill of quantities Drawings CM/CS

12. Design-bid-build Cont’d • Owner • Consultant Contractor consultant

13. Contract goals :

14. Contract Types • Fixed prices or lump sum contract • 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

18. Project Time Management Processes 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

19. Activity Definition Project schedules grow out of the basic document that initiates a project: • Project data includes start and end dates and • Budget information • 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

20. TOOLS • Gantt or bar charts • Network analysis • The arrow diagram • The precedence diagram • Critical path analysis • Techniques for shortening a project schedule

21. Simple example (Project Planning…Gilland Chart): • 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.

22. Float • This activity: • Can not start before mid-Feb. • Must be completed by mid-April. • It will take about 4 weeks to complete. (a) (b) The term “float” implies that the activities have certain freedoms. Float time is not free time Responsibility

23. Basic types of time relationships: • An activity (successor) requires its (pre decessor) to be complete before it can start • Two activities must be complete before a successor can start. The two activities run in parallel A finish – to – start relationship A finish – to – finish relationship A start – to – start relationship

24. Resources on a bar chart 2 2 2 2 4 2 2 • Resources required: • Manpower (different types) • Equipment • Cash • Subcontractors (different types)

26. The plant-site relationship:Variability in basic requirements : • Area requirements, m2 • Water requirements, m3 /hr • Utility requirements Electrical power Telephone Natural gas Waste disposal( gas, liquid, solid ) • Special Labor requirements N.B: Mention Clusters & 14 Factors (not constant)

27. Global Manufacturing Location Decision Country Factors Favorable economic, political, cultural conditions Technological Factors Fixed costs relatively low Minimum efficient scale Scale of output a plant needs to realize scale-economies Market demand must be sufficient to reach this scale Flexible manufacturing-lean production-mass customization Product features Value-to-weight ratio Universal needs

28. 1. Information required to select a site 1.1 Maps and surveys Maps Surveys source surveying contractor scale benchmark date contours The Egyptian Survey Authority

29. 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

30. 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

31. Redundant Control System

32. Statement of the problem Siting of chemical process plants 1. Two risk domains 2. Three layers of interaction Industry Society Industry internal risk Industry external risk Environment The field of technological risk assessment The field of land-use planning GAP

33. 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

34. 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”

35. 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

36. General Factors in Planning Layouts: • New site development vs. addition to a previously developed site. • Future expansion. • Economic distribution of services – water, steam, power, gas. • Weather conditions, outdoor vs. indoor construction. • Safety considerations – possible hazard of fire, explosion or fumes. • Building code requirements. • Waste Disposal Problems. • Sensible use of Floor & Elevation Space.

37. Data Requirements for the preparation of a conceptual layout: • Equipment list with approximate dimensions. • Process flow sheets or preliminary P & ID’s showing relative elevations. • Off-site requirements – buildings, tank farms, diked areas,railroads, cooling towers, storage areas, • Hazard considerations. • Process buildings and/or structure requirements (open/closed). • Future expansion considerations.

38. Low Hazard Process Areas 600 x 500 ft. Atmospheric Tankage 300 x 600 ft. Offices 200 x 200 ft. 200 ft. Property Line Total Land Area = 45 acres Parking 100 ft. 100 ft. 1300 ft. NM 200 ft. Maintenance Warehouse 100 ft. Spacing around flare based on radiant heat calculations 200 x 600 ft. Utilities 200 x 300 ft. Spacing based on local building codes Flare 200 x 300 ft. NM 1500 ft.

39. Typical layout assembly plan

40. CAD generated three dimensional models (Sub-process Area) :

42. Economic & Technical Factors in Chemical Plant Layout

44. Input data to Plot Plan

46. Important Equipments Mentioned • Drum • Pumps • Reactors • Towers • Pipe Racks N.B : Installation and Precautions

47. Why reliability?Operational Excellence is biggest profit contributor Company Profit Operational Excellence is biggest controllable contributor to sustainable profit. Operational Excellence Reliability Excellence Operational Excellence needs a reliable foundation: • People Processes • ToolsMetrics • Mention KPI ABB Confidential and Proprietary Information

48. 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. Aberdeen’s MethodologyEnd-User Investigation: PACE Framework P A C E

49. Decisions for Asset Lifecycle Management Asset reliability and maintenance 81% New asset procurement 65% Spare parts management 64% Asset repair / refurbish / overhaul 60% Training and certification 52% Asset commissioning 47% Asset decommissioning 41% Safety - Employee and Asset 36% Environment and energy management 32% 0% 25% 50% 75% 100% Survey Question: Please describe which of the following decisions you influence?