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PlantPlant EngineeringEngineering

JulyJuly--AugustAugust 20122012

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City LappeenrantaModule Plant Engineering and Project ManagementECTS 3Date July 30th - August 3rdLecturer Toni RauvantoLecturer's Insitute Saimaa University of Applied SciencesPrerequisites No

Objectives to learn key functions and issues in global industrial project focusing on engineering and more closely mechanical engineer’s point of view

Contents Main functions and tasks in global industrial project, engineering in global industrial project, project lifecycle, engineering disciplines and co-operation during project, case “Finnish-based global engineering and consulting company” and real life engineering examples

Indicative reading Material to be sent by e-mail to students during lectures.

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Learning modes: Instructor

Workload: 40 hours inc. lectures, case examples, exercises, self-study.

Max. Students 25

Assesment: An examination (possibility to have 2 examinations if agreed during the 1st week). In examination there will be five exercises; where maximum is 5 x 6 = 30 points. In order to pass you should get at least around 45 % of maximum points.

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What kind of questions it is included in upcoming daily examinations:

1) 6 Statements (statements shall be marked ”right” or ”wrong”. Correctguess gives 0 points without correct explanation of the given stance.

6 6 pointspoints

2) Explanation of 6 statements by using the 2..3 correct sentences.6 6 pointspoints

3) Essay3 3 pointspoints

4) Evaluation of given terms. ”What is a difference between terms XXX and YYY?”

3 3 pointspoints

18 18 pointspoints

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Plant Engineering, August 2010Plant Engineering, August 20101.1. Project lifecycle Project lifecycle 2.2. Main functions and tasks in global industrial Main functions and tasks in global industrial

projectproject3.3. Engineering in global industrial projectEngineering in global industrial project4.4. Engineering disciplines and coEngineering disciplines and co--operation during operation during

projectproject5.5. Real life engineering examples Real life engineering examples 6.6. Case “FinnishCase “Finnish--based global engineering and based global engineering and

consulting company”consulting company”

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01 Project lifecycle01 Project lifecycle

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Project phasesProject phases

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Project life cycleProject life cycle

•• Before investment project reaches the implementation phase, Before investment project reaches the implementation phase, different kind of predifferent kind of pre--feasibility studies, needed for preparing the feasibility studies, needed for preparing the project, may have taken a long time, often years.project, may have taken a long time, often years.

•• After all, through picking out the best ideas at different stages, After all, through picking out the best ideas at different stages, only a small part of studied plans get implemented.only a small part of studied plans get implemented.

•• Project life cycle can be divided into phases. See the example of Project life cycle can be divided into phases. See the example of rebuild project phases on the next page.rebuild project phases on the next page.

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Investment planningInvestment planning

•• Through preThrough pre--feasibility studies and prefeasibility studies and pre--engineering the engineering the investment ideas and project plans are selected for investment ideas and project plans are selected for implementing. Performed preimplementing. Performed pre--engineering / preengineering / pre--feasibility feasibility studies guarantee that detailed engineering will be successful.studies guarantee that detailed engineering will be successful.

•• PrePre--feasibility study is an overall study for evaluating if the feasibility study is an overall study for evaluating if the project is worth implementing, and this study produces the project is worth implementing, and this study produces the following documents:following documents:

Investment calculation, accuracy 0...+30%Investment calculation, accuracy 0...+30%Technical specificationsTechnical specificationsOverall time scheduleOverall time schedule

•• PrePre--engineering aims at the investment decision.engineering aims at the investment decision.

•• PrePre--engineering documentation includes:engineering documentation includes:Basic data of implementation phase:Basic data of implementation phase:Investment calculation, accuracy 0...+10 %Investment calculation, accuracy 0...+10 %Technical specificationsTechnical specificationsMain time schedulesMain time schedulesPreliminary layoutPreliminary layoutPreliminary process diagramsPreliminary process diagrams

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Launch of ProjectLaunch of Project

•• In implementation phase the project launching includes among In implementation phase the project launching includes among other things :other things :

Organization and resource planOrganization and resource planProject planProject planKickKick--off meetings / internal, with Client and main suppliers off meetings / internal, with Client and main suppliers Information flow managementInformation flow management

•• Organization chart is formed in accordance with the project Organization chart is formed in accordance with the project requirements. requirements.

•• Resource plan ensures suitable resources being available for Resource plan ensures suitable resources being available for the project during the whole project period.the project during the whole project period.

•• Project plan includes guidelines for project partners and Project plan includes guidelines for project partners and introduces the plan how to execute the project. This plan introduces the plan how to execute the project. This plan covers among others:covers among others:

Management of documentationManagement of documentationOrganizationsOrganizationsInstructions for work safety and permit proceduresInstructions for work safety and permit proceduresMain time schedulesMain time schedules

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Project coordinationProject coordination•• Project manager is responsible for coordination and this task Project manager is responsible for coordination and this task

covers the following essential items:covers the following essential items:Leading the work progress and coordinating separate partial Leading the work progress and coordinating separate partial sectionssectionsControl of time schedulingControl of time schedulingControl of documentationControl of documentationCoordination of resourcesCoordination of resourcesMeeting practiceMeeting practiceClient relationsClient relationsReportingReportingQuality controlQuality control

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Engineering and procurementEngineering and procurement

•• Basic engineering is started being based on preBasic engineering is started being based on pre--engineering documentation engineering documentation including e.g. information for purchases and basic data for detailed including e.g. information for purchases and basic data for detailed engineering, as well. engineering, as well.

•• PI Diagrams and layouts will be frozen after the basic engineering phase.PI Diagrams and layouts will be frozen after the basic engineering phase.

•• Overall, engineering and purchasing time schedules are prepared Overall, engineering and purchasing time schedules are prepared immediately the project has started, and while project proceeding the immediately the project has started, and while project proceeding the schedules will be updated.schedules will be updated.

•• Installation and civil works will be carried out in accordance with the Installation and civil works will be carried out in accordance with the documents prepared during detailed engineering. documents prepared during detailed engineering.

•• Installation contracts of piping, electrification and instrumentation as well Installation contracts of piping, electrification and instrumentation as well as of tanks and structural steels are purchased using the engineering as of tanks and structural steels are purchased using the engineering documents.documents.

•• At this stage also the final time schedules of installation and civil works are At this stage also the final time schedules of installation and civil works are prepared.prepared.

•• It depends on the correctness of engineering documents how succesful the It depends on the correctness of engineering documents how succesful the installation phase will be. For this reason the project has the quality installation phase will be. For this reason the project has the quality assurance plan that comprises e.g. engineering audits, document checking assurance plan that comprises e.g. engineering audits, document checking and regular meeting practice.and regular meeting practice.

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Installation and testing phasesInstallation and testing phases

•• In In RebuildRebuild projects, projects, in particularin particular, , the plans and scheduling for the plans and scheduling for preparation and shutdown works shall be performed thoroughly.preparation and shutdown works shall be performed thoroughly.

•• Work load during the main shutdown will be decreased. This Work load during the main shutdown will be decreased. This means that all possible preparation works utilizing intermediate means that all possible preparation works utilizing intermediate shutdowns are carried out to keep the scheduled main shutdown shutdowns are carried out to keep the scheduled main shutdown dates.dates.

•• It has been proved that a very important part in installations at It has been proved that a very important part in installations at the site is the assistance design engineers can offer regarding the site is the assistance design engineers can offer regarding installation supervision, testing, startinstallation supervision, testing, start--up and training. Especially up and training. Especially these services are asked for in the following sections:these services are asked for in the following sections:

ProcessProcessPipingPipingElectrificationElectrificationInstrumentationInstrumentation

•• This also plays an important role in improving the professional This also plays an important role in improving the professional skills of personnel on the client’s and engineering company’s skills of personnel on the client’s and engineering company’s sides.sides.

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Project completionProject completion•• Project completion covers the preparation of final documentation Project completion covers the preparation of final documentation

(as(as--built), and completion meetings with the suppliers.built), and completion meetings with the suppliers.•• In order to improve engineering company’s activities the Client is In order to improve engineering company’s activities the Client is

asked for submitting them the feedback.asked for submitting them the feedback.

Maintenance engineeringMaintenance engineering•• In addition to normal investment project activities engineering In addition to normal investment project activities engineering

companies also render services to their clients in maintenance companies also render services to their clients in maintenance engineering at the plants as per their local service policy.engineering at the plants as per their local service policy.