Process Plant Design Project Management from Inquiry to Acceptance

by Helmus, Frank Peter

• ISBN13: 9783527313136
• ISBN10: 3527313133
• Edition: 1st
• Format: Hardcover
• Copyright: 2008-03-03
• Publisher: Wiley-VCH

Summary

This book describes the fascinating wealth of activities as they occur in the design, construction and commissioning of a chemical plant - a jigsaw puzzle of the work of chemical engineers, chemists, constructors, architects, electrical engineers, process automation engineers, economists and legal staff.The author first takes the reader through the conceptual phase, in which the economic relevance and environmental impact need to be considered and supplemented by accurate estimates of capital requirements and profitability.This phase ends with the choice of an appropriate engineering firm and the conclusion of the contract, after which the reader is guided through all aspects of the implementation phase from the engineering of the chemical plant to commissioning, equipment and material procurement, the erection phase and the successful test run, after which the new facility is handed over to its owner.The book also illustrates many potential sources of errors by means of examples from practice, and how, aside professional skills, teamwork and communication are also absolutely essential to keep such a complex project on track.

Author Biography

Frank Peter Helmus studied chemical engineering in Aachen, Germany and obtained the PhD for his work on membrane processes. Afterwards he worked as a project manager in the Babcock Balcke-Dürr Company. During his industrial career he carried out several medium sized projects (waste water treatment plants up to 18 million Euro), some of them abroad, as a project manager from the beginning to the end. Since 1998 he is professor for chemical engineering at the University of Applied Sciences in Osnabr?is main field of activity is mechanical processes and process plant design. He is related to his former field of activities by performing claims management courses for senior engineers. His research activities focus on waste water treatment.

Table of Contents

Preface	p. XVII
Acknowledgements	p. XIX
Introduction	p. 1
General remarks on process plant design	p. 1
Project	p. 2
Demands on project engineers	p. 6
Overview of activities	p. 8
Project Planning	p. 13
Operator	p. 13
Product development	p. 14
Plant type	p. 14
Location/kind of premises	p. 15
Capacity/availability/lifespan	p. 16
Degree of automation	p. 17
Legal requirements	p. 17
Costs	p. 18
Investment	p. 19
Operating costs	p. 21
Inquiry/invitation to tender	p. 23
Project controlling	p. 27
Plant manufacturer	p. 28
Risk analysis	p. 28
Basic engineering	p. 30
Process development	p. 30
Balancing	p. 32
Basic and process flow diagram	p. 34
Materials concept	p. 36
Main apparatus	p. 42
Layout	p. 45
Quotation	p. 48
Quotation price	p. 48
Optimization	p. 49
Contract negotiations	p. 53
Contract	p. 55
General	p. 56
Definitions	p. 56
Order basis	p. 56
Regulations	p. 57
Labour employment	p. 58
Subcontractors	p. 58
Project documentation	p. 59
Technical part	p. 60
Contractor's scope of supply and services	p. 60
Employer's scope of supply and services	p. 62
Commercial part	p. 63
Deadlines/penalties	p. 63
Warranties/penalties	p. 66
Defects/acceptance	p. 67
Prices/terms of payment/bonds	p. 69
Alterations/claims	p. 70
Termination/suspension	p. 74
Insurance	p. 75
Secrecy	p. 76
Severability clause	p. 77
Coming into effect	p. 77
Signature policy	p. 78
Project execution	p. 81
Project organization	p. 81
Project structures	p. 82
Systematics	p. 90
Project manual	p. 90
Correspondence system	p. 92
Revision service	p. 93
Cost monitoring	p. 95
Time scheduling/monitoring of dates	p. 96
Computers in plant manufacturing	p. 97
Approval planning	p. 102
Component procurement	p. 103
Vessels	p. 110
Pumps	p. 111
Piping and instrumentation diagrams	p. 117
E/MC-technology	p. 135
Electrical engineering	p. 136
Measurement engineering	p. 137
Control engineering	p. 143
Layout and building design	p. 147
Layout design	p. 147
Building design	p. 150
Piping planning	p. 154
Documentation	p. 161
Erection	p. 165
Excavation and civil works	p. 166
Component assembly	p. 167
Pipe assembly	p. 169
Assembly E/MC technology	p. 171
Insulations	p. 172
Plant marking	p. 173
Commissioning	p. 175
Training	p. 176
Cleaning	p. 176
Pressure tests	p. 177
Functional tests	p. 178
System tests	p. 179
Cold commissioning	p. 180
Warm commissioning	p. 180
Warranty run/acceptance	p. 182
Index	p. 183
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