Skidded Process Equipment – Installation, Startup and Commissioning
Principal Engineer Hyde Engineering & Consulting, Inc.
Installatio n Challenges Challenges Dimensions: •
,
• Main Mainte tena nanc nce e acc acces ess s • Move Moveme ment nt into into buil buildi ding ng • Move Moveme ment nt thr throu ough gh bui build ldin ing g
Weight limitations Timing: • Skids Skids often often placed placed early early duri during ng construction construction – contingency contingency planning
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Installatio n Challenges Challenges (cont .) Protection during construction Interconnecting Piping: • Inte Interf rfac aces es – line line up/ up/sl slop opin ing g • Walkd Walkdow own n befo before re inst instal alli ling ng dryw drywal alls ls
Business interruption: • Temp Tempor orar ary y egr egres ess s • Clea Cleanr nroo oom: m: Tent Tentin ing g • Uti Utility lity tie tie-i -ins ns
Startu Startu p Challenges Challenges Safety: • The The fir first st time time you you turn turn itit on on • Plan Plan & con conta tain in dang danger er • Is ever everyt ythi hing ng wir wired ed? ? • Prot Protec ectt your your tes testi ting ng equipment • discs?
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Startu Startu p Challenges Vendor Support: • Plan Plan + use use supp suppor ortt wisely • Leve Levera rage ge know knowle ledg dge e • Turno Turnove verr and and Punc Punchl hlis istt
SME: Startup and initial tuning
Commissioning Test plan: • • Util Utilit ity y Veri Verifi fica cati tion on • Cont Control rol Syst System em Hardw Hardware are / Calibration • Softw oftwar are e Test Testin ing g • Covera e Testin • Spare Parts • TO TOP P Comp Complleti etion
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Superskids Design Support and Commissioning on site: • • FAT IQ/parts of OQ • Wet Wet Tes Testi ting ng / star startu tup p • TO TOP P revie review w / comp comple leti tion on
ASTM-E2500: A STM-E2500: Speed Sp eed & Foc Fo c u s SME Leads the effort Risk assessments: • Focus Focus on the critic critical al attribu attributes tes • Take Take risk risk and and budg budget et for for cont conting ingenci encies es
Verification: • Levera e FAT artner with vendor • Supple Supplemen mentt with with Client Client testin testing g
TOP’s: • Revi Review ew duri during ng FAT FAT • Electronic
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Contact Info Ronald Berk Principal Consultant Hyde Engin Engin eering eering + Cons Cons ulti ng, Inc.
[email protected] 303-817-9520
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“Talkin Sho ” Round Table Discussion on Skid Based Process Equipment Design & Engineering : -
Technolo Technolo gy Transfer Transfer – Understanding Understanding Clients needs needs or URS URS • URS URS user user re uire uireme ment nt s ecif ecific icat atio ion n is a ke ke elem elemen entt in in ski skid d des desii n but is quite often not available •A detailed technology transfer is necessary •Make sure both engineer and the client understand what the parameters are. •Basis of Design •Size constraints •Accessibility • ean ng requ remen s •Steaming requirements(SIP) •Automation •Location –Clean room, Grey Space , Utility Room, Outside
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Engineering Documentation
•Process Flow Diagram (PFD) •Specifications •Piping and Instrument Diagram (P&ID) •3D Model •Equipment Arran ement •Piping GA
•Extremely important to have a well defined P&ID
Design Steps •Feasibility •Conceptual •Preliminary •Detail •CA (construction administration) •Start-up and Commissioning
•Keep an open mind about new innovations, equipment, components and technology. technology. They are being improved upon continuously
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Use a Control drawing when specify equipment
Spatial Requirements •Installation •Operability •Maintenance •Cleanable •Insulation
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Use Design tools to help alleviate field problems
Utilities Know the utility requirements • Power • Steam • Wate Waterr (USP (USP,, WFI) WFI) • Gases •
as e
ra na nage
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Design Design Tools Proper use of design tools helps eliminates surprises in the field.
Lets the operator know how they will be able to access their equipment
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ISPE ISPE Talkin Talkin g Sho p Skid Based Process Equipment Part Part 2: Equipment Buy Out, Contracts, Etc. Etc. Date:
21 April 2011
RJ MacLean Project Engineering, Biogen Idec
Agenda, Part 2 • Introdu Introductio ction, n, a view view from from each each side side of fence fence • Owne Ownerr vs. vs. Sk Skid id Vend Vendor or • Buy Buy out out of of the the equip equipmen mentt • Term Terms s and and cond condit itio ions ns • • Wrap up
2 Form:GEF-012 Rev 2.0
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Introduction Owner and skid vendor are different , • Operate Operate in diff differen erentt competi competitive tive envir environme onments nts • Owner: Owner: primaril primarily y inter internall nally y focuse focused d • Sk Skid id Vend Vendor: or: prima primaril rily y exter external nally ly focu focused sed • Project Project time time horizon horizons s are not the same Both sides must recognize the strengths and weaknesses of the other.
3 Form:GEF-012 Rev 2.0
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These are very different firms! $
$
$ MICROSOFTCORPORATION
Management
Purchasing
Accounts Payable
Research & Development Accounting
Internal Customers
Finance
Quality Assurance ance
AE
Owner
Skid Vendor
Design/Engineering
Suppliers
Suppliers
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Suppli ers
Warehouse/Kitting
Quality Assurance
Fabrication
FAT
Shipping
Other Customers
Suppliers
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Owner vs. Skid Vendor Skid Vendor Priorities:
Owner’s Priorities: .
os
.
er a n y
n ers an a n scope
2. Sc Sche hedu dule le Cert Certai aint nty y
2. Mana Manage ge dem deman and d
3. Quality
3. Owner: Owner: stay stay out out of of the way
4. Effi Effici cien entt Del Deliv iver ery y
4. Mini Minima mall change changes s
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Owner vs. Skid Vendor • Understa Understand nd what what each each other other need to succee succeed d • Trus Trustt is is cri criti tica call • Once broken, broken, it will will be a long project project
6 Form:GEF-012 Rev 2.0
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Owner vs. Skid Vendor Owners Remember This: 1. The The skid skid biz biz is is not not easy easy 2. If itit were were so easy easy then then do do it yours yoursel elf f 3. Don’t Don’t play play “where’ “where’s s waldo” waldo” with with specs specs • •
If somet somethin hing g is is impo importa rtant, nt, highl highligh ightt itit Avo Av oid a la late spec dum dump p
4. Unwr Unwrit itte ten n spe specs cs 5. Stay Stay out out of of the the OEM OEM workf workflow low • • 7 Form:GEF-012 Rev 2.0
Docs Docs:: Don’ Don’tt ask ask for for what what you you don don’t ’t nee need d Tags Tags:: Don’ Don’tt chan change ge them them!! 7
Owner vs. Skid Vendor Skid Vendors Remember This: 1. Life Life on on the the insi inside de is is comp comple lex x 2. Don’t Don’t be high high main mainten tenanc ance e •
Figur Figure e out out ways ways to save save the the own owner er time time
•
Time Time is is the the owne owner’ r’s s ene enemy my,, don’ don’tt was waste te it
3. The “proj “project ect”” has barely barely begun begun when when the the skid skid arrives at the owner’s dock 4. The owner owner wants wants to “forget “forget about about you” you” • • • 8 Form:GEF-012 Rev 2.0
The owner owner does does not have have enoug enough h time/ time/int intern ernal al reso resourc urces— es—be be efficient with comms Be reli reliab able, le, meet meet you yourr sche schedu dule le com commi mitm tmen ents ts Own Own the the sch sched edul ule: e: DRIV DRIVE E THE THE OWN OWNER ER 8
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Buy Out—Owner Initial Considerations 1. Trust •
Leve Levera rage ge rela relati tion onsh ship ips s
2. Keep Keep vendo vendorr base base smal smalll but but acti active ve •
Why Why rere-tr trai ain n ifif you you don’ don’tt hav have e to? to?
•
Reus Reuse e exi exist stin ing g con contr trac acts ts
3. Loca Locall is be best •
Tim Time, not cost is key key
4. Don’t Don’t send send out an RFP RFP to a firm firm that that you don’t don’t intend to use
9 Form:GEF-012 Rev 2.0
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Buy Out—Vendor Initial Considerations 1. Trust •
Leve Levera rage ge rela relati tion onsh ship ips s
2. Recogniz Recognize e that that the the owner owner must must operat operate e and quote in a competitive environment 3. Don’t Don’t prom promis ise e what what can’t can’t be done done 4. If you can’t can’t work work with with a firm firm don’t don’t bid 5. If somet somethin hing g doesn’t doesn’t sound sound right right in the the RFP, RFP, it likely is not. Get it clarified.
10 Form:GEF-012 Rev 2.0
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T’s & C’s 1. The contract contract templat template e should should be be part part of the RFP •
en or: later.
s s your me me o commen an e
.
o
2. Defin Define e mil milest estone one payme payment nts s •
What is is a 30% re review
•
What What is is an “appro “approve ved d gene general ral arran arrange gemen ment”? t”?
•
.
•
Vend Vendor or:: Don’ Don’tt be stup stupid id with with invo invoic ices es
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T’s & C’s (cont.) 3. Chan Change ge order rders s • • • •
How will will a cha chang nge e be exec execute uted d if a contr contrac actt is in lace? Owner: Owner: Recog Recogniz nize e the the OEM cost cost struc structur ture e Vend Vendor or:: Owne Ownerr nee needs ds prom prompt pt cost cost cert certai aint nty y Both Both:: The The C/O C/O proc proces ess s is is the the most most like likely ly plac place e to to break trust.
4. Penal Penalti ties es and Incen Incenti tives ves • •
Vend Vendor or:: Insi Insist st on ince incent ntiv ives es if owne ownerr ins insis ists ts on penalties
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Fabrication and FATs
1.
Owner: Owner: Conside Considerr multi multiple ple in in proce process ss inspect inspection ions s
• •
. 3. 4. 5.
o : o s respons e or e oc Both: oth: How How to to st staff aff the the FA FAT? T? Spray Spray ball ball testin testing g should should be be done at vesse vessell vendor vendor,, not the OEM OEM shop Owne Owner: r: Shor Shortt FAT FAT prot protoc ocols ols are are best best • •
Less Less is more more.. Get Get in and and get get out. out. What What can can be be lev lever erag aged ed dow down n the the roa road d in in C&V C&V? ?
•
Loca Locall I/O I/O and and loo loop p che check cks s go go a long long way way
. 7.
Avoid su surprises rd 3 party—tell the vendor in advance
’ Get wet
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Wrap Up 1. Understa Understand nd each other’s other’s priorit priorities ies 2. Buil Build d and and maint maintai ain n trus trustt 3. Both Both:: Look Look for for retu return rn busi busine ness ss 4. Time Time is is the the enem enemy y for for the the owne owner r 5. Scope Scope control control and under understa standin nding g of scope scope is key for the vendor
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