30/07/2012 30/07/2012 11

Plant Plant Engineering Engineering

July July- -August August 2012 2012
2
30/07/2012 30/07/2012 Plant Engineering, August 2012, Toni Plant Engineering, August 2012, Toni
Rauvanto Rauvanto
22
City Lappeenranta
Module Plant Engineering and Project Management
ECTS 3
Date July 30th - August 3rd
Lecturer Toni Rauvanto
Lecturer's Insitute Saimaa University of Applied Sciences
Prerequisites No
Objectives to learn key functions and issues in global industrial project
focusing on engineering and more closely mechanical
engineers 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.
30/07/2012 30/07/2012 33
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.
30/07/2012 30/07/2012 44
What kind of questions it is included in upcoming daily
examinations:
1) 6 Statements (statements shall be marked right or wrong . Correct
guess gives 0 points without correct explanation of the given stance.
6 6 points points
2) Explanati on of 6 statements by using the 2..3 correct sentences.
6 6 points points
3) Essay
3 3 points points
4) Evaluation of given terms. What is a difference between terms XXX and
YYY?
3 3 points points
18 18 points points
30/07/2012 30/07/2012 55
Plant Engineering, August 2010 Plant Engineering, August 2010
1. 1. Project lifecycle Project lifecycle
2. 2. Main functions and tasks in global industrial Main functions and tasks in global industrial
project project
3. 3. Engineering in global industrial project Engineering in global industrial project
4. 4. Engineering disciplines and co Engineering disciplines and co--operation during operation during
project project
5. 5. Real life engineering examples Real life engineering examples
6. 6. Case Finnish Case Finnish- -based global engineering and based global engineering and
consulting company consulting company
6
30/07/2012 30/07/2012 Plant Engineering, August 2010, Toni Plant Engineering, August 2010, Toni
Rauvanto Rauvanto
66
01 Project lifecycle 01 Project lifecycle
30/07/2012 30/07/2012 77
Project phases Project phases
30/07/2012 30/07/2012 88
Project life cycle Project life cycle
Before investment project reaches the implementation phase, Before investment project reaches the implementation phase,
different kind of pre different 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.
30/07/2012 30/07/2012 99
Investment planning Investment planning
Through pre Through pre- -feasibility studies and pre feasibility 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 pre implementing. Performed pre--engineering / pre engineering / pre- -feasibility feasibility
studies guarantee that detailed engineering will be successful. studies guarantee that detailed engineering will be successful.
Pre Pre- -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 specifications Technical specifications
Overall time schedule Overall time schedule
Pre Pre- -engineering aims at the investment decision. engineering aims at the investment decision.
Pre Pre- -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 specifications Technical specifications
Main time schedules Main time schedules
Preliminary layout Preliminary layout
Preliminary process diagrams Preliminary process diagrams
30/07/2012 30/07/2012 10 10
Launch of Project Launch 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 plan Organization and resource plan
Project plan Project plan
Kick Kick--off meetings / internal, with Client and main suppliers off meetings / internal, with Client and main suppliers
Information flow management Information 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 documentation Management of documentation
Organizations Organizations
Instructions for work safety and permit procedures Instructions for work safety and permit procedures
Main time schedules Main time schedules
30/07/2012 30/07/2012 11 11
Project coordination Project 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
sections sections
Control of time scheduling Control of time scheduling
Control of documentation Control of documentation
Coordination of resources Coordination of resources
Meeting practice Meeting practice
Client relations Client relations
Reporting Reporting
Quality control Quality control
30/07/2012 30/07/2012 12 12
Engineering and procurement Engineering and procurement
Basic engineering is started being based on pre Basic 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.
30/07/2012 30/07/2012 13 13
Installation and testing phases Installation and testing phases
In In Rebuild Rebuild projects, projects, in particular in 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, start installation 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:
Process Process
Piping Piping
Electrification Electrification
Instrumentation Instrumentation
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 clients and engineering companys skills of personnel on the clients and engineering companys
sides. sides.
30/07/2012 30/07/2012 14 14
Project completion Project 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 companys activities the Client is In order to improve engineering companys activities the Client is
asked for submitting them the feedback. asked for submitting them the feedback.
Maintenance engineering Maintenance 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.