Handbook for Process Plant Project Engineers

This excellent book systematically identifies the issues surrounding the effective linking of project management techniques and engineering applications. It is not a technical manual, nor is it procedure-led. Instead, it encourages creative learning of project engineering methodology that can be applied and modified in different situations.In short, it offers a distillation of practical 'on-the job' experience to help project engineers perform more effectively. While this book specifically addresses process plants, the principles are applicable to other types of engineering project where multidisciplinary engineering skills are required, such as power plant and general factory construction.It focuses on the technical aspects, which typically influence the configuration of the plant as a whole, on the interface between the various disciplines involved, and the way in which work is done - the issues central to the co-ordination of the overall engineering effort.It develops an awareness of relationships with other parties - clients, suppliers, package contractors, and construction managers - and of how the structure and management of these relationships impact directly on the performance of the project engineer. Readers will welcome the author's straightforward approach in tackling sensitive issues head on.COMPLETE CONTENTS Introduction A process plant A project and its management A brief overview The engineering work and its management The project's industrial environment The commercial environment The contracting environment The economic environment Studies and proposals Plant layout and modelling Value engineering and plant optimization Hazards, loss, and safety Specification, selection and purchase Fluid transport Bulk solids transport Slurries and two-phase transport Hydraulic design and plant drainage Observations on multidiscipline engineering Detail design and drafting The organization of work Construction Construction contracts Commissioning Communication Change and chaos Fast-track projects Advanced information management Project strategy development Key issues summary

Peter Watermeyer is currently Executive Director, Engineering for Bateman BV

Foreword	p. ix
Acknowledgements	p. x
Introduction	p. 1
What's so special about process plant projects?	p. 1
The structure and components of this book	p. 3
Methodology of presentation	p. 5
Getting it right	p. 7
A Process Plant and a Project
A Process Plant	p. 13
Basic process design elements	p. 13
The processed materials and the process	p. 18
The process design/detail design interface	p. 20
A Project and its Management: A Brief Overview	p. 23
The project	p. 23
Starting the project	p. 25
Managing the project	p. 27
The Engineering Work and Its Management	p. 31
Planning the engineering work	p. 31
Doing the engineering work	p. 40
Managing schedule, cost, and quality	p. 41
Co-ordinating engineering work	p. 44
Management of engineering resources	p. 46
Environment
The Project's Industrial Environment	p. 51
The industry and the client	p. 51
The client and the project management	p. 55
The process plant project industry: the 'indirect cost' of a plant	p. 56
The Commercial Environment	p. 59
Principles of procurement and contract	p. 59
The Contracting Environment	p. 65
Ways of building a plant	p. 65
The engineering contractor	p. 70
The project engineer	p. 72
Conclusion	p. 75
The Economic Environment	p. 77
Plant profitability	p. 77
Lifecycle considerations and 'trade-off' studies	p. 78
The real world of costs and values	p. 82
Project engineering and management work	p. 83
Conceptual Development
Studies and Proposals	p. 91
Feasibility studies	p. 91
Proposals	p. 94
Estimating project costs	p. 94
Risk	p. 97
Accuracy	p. 99
Contingency	p. 101
Plant Layout and Modelling	p. 105
Layout	p. 105
Design presentation and modelling	p. 112
Value Engineering and Plant Optimization	p. 117
Value engineering	p. 118
Plant optimization models	p. 120
Hazards, Loss, and Safety	p. 123
Hazard identification	p. 124
Designing for safety	p. 127
Commissioning	p. 131
Plant modifications	p. 132
Engineering Development and Detail
Specification, Selection, and Purchase	p. 135
Procurement	p. 135
Specification	p. 138
Specification as a document for bidding	p. 138
Specification as a reference for work performance	p. 141
The selection of equipment	p. 141
Technical appraisal of equipment bids	p. 143
Inspection and quality control	p. 145
Planning inspection work	p. 148
Expediting	p. 150
Fluid Transport	p. 153
A brief note on liquid-pumping systems design	p. 153
Gases	p. 162
Piping engineering and its management	p. 167
Some concluding comments on piping layout for pumps and compressors	p. 170
Bulk Solids Transport	p. 173
Bulk solids flow	p. 173
Conveyors	p. 175
Feeders	p. 181
Safety and environmental health	p. 183
Slurries and Two-Phase Transport	p. 185
Slurry transport	p. 185
Piping design	p. 188
Tanks and agitation	p. 189
Pneumatic conveying	p. 191
Pipework reactions	p. 192
Hydraulic Design and Plant Drainage	p. 195
Hydraulic design	p. 195
Plant drainage	p. 201
Observations on Multi-Discipline Engineering	p. 203
Structural design considerations	p. 203
Plant and equipment loads	p. 205
Civil engineering	p. 207
Electrical engineering	p. 209
Instrumentation and control	p. 212
Detail Design and Drafting	p. 217
Structures	p. 218
Piping	p. 221
Vessels	p. 227
Chutes, bins, and hoppers	p. 229
Civil design	p. 230
Instrumentation and control	p. 233
Electrical design	p. 236
Other technical specialities and consultants	p. 238
Overview of the design process	p. 239
General arrangement drawings and models	p. 240
Traditional Documentation Control	p. 243
More on Management
The Organization of Work	p. 249
Packaging work	p. 249
Procedures	p. 254
Construction	p. 257
Survey and setout	p. 258
Site management	p. 258
Technical information for construction	p. 259
Site materials management	p. 260
Heavy lifts	p. 261
The 'site and office' relationship	p. 262
Construction Contracts	p. 265
Structuring contracts	p. 265
Structuring payment to contractors	p. 269
Claims	p. 270
Commissioning	p. 273
Safety during commissioning	p. 276
Communication	p. 277
Change and Chaos	p. 281
Change	p. 281
Chaos	p. 283
Fast-Track Projects	p. 289
Case study A: Fabulous Fertilizers' new plant	p. 292
Case study B: Magnificent Metals' new gold plant	p. 293
Advanced Information Management Systems	p. 297
Final Cycle--Strategies for Success
Project Strategy Development	p. 305
Is the target correct?	p. 307
How do we get there?	p. 308
What are the major problems?	p. 309
Key Issues Summary	p. 311
Key project or study issues at the conceptual stage	p. 311
Key issues at the project execution phase	p. 311
Key issues for the conduct of the individual engineer or engineering business unit	p. 313
General business issues	p. 313
Jargon	p. 315
Definition of design parameters	p. 316
Design Criteria Checklist	p. 317
Plant performance	p. 319
Plant site	p. 319
The process	p. 319
Basic plant design features	p. 320
Design features for equipment (mechanical, instrumentation, and electrical)	p. 320
Design methodology and standardization	p. 320
Design verification and approval plan	p. 321
Design and plant documentation for client	p. 321
Index	p. 323
Table of Contents provided by Syndetics. All Rights Reserved.

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Handbook for Process Plant Project Engineers

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