Process Plant Construction

This handbook introduces engineers, project and construction managers, and senior technicians to a methodology for the management of quality on a process plant construction site. The eleven chapters of the handbook define the roles and appellations of the parties involved in a project as well as outlining the fundamental strategic and contractual orientations to be decided. The ISO 9000 series of standards are examined within the context of the process plant construction site. A study is then made of the roles of the organizations involved and of the interfaces between them. Special attention is given to document and materiel control, followed by a review of the various monitoring and feedback systems to keep the project on track moving towards the ultimate goal of satisfactory construction completion leading to turnover. Model procedures are proposed, complete with forms attached, and a number of case studies are included to illustrate the practical application of the principles presented. Process Plant Construction: a handbook for quality management is completed by appendices covering Civil Works & Buildings, Mechanical Equipment, HVAC, Welding, Structural Steelwork, Piping, Electrical Installation, Instrumentation & Control, Painting, and Thermal Insulation. Each appendix, aimed at the non-specialist, presents briefly for the discipline concerned the nature of the works likely to be met on site, evokes the parties involved and highlights quality issues to be addressed. Typical inspection and test programs are outlined.

The book covers all stages of process plant projects from initiation to completion and handover by describing the roles and actions of all functions involved. It discusses engineering, procurement, construction, project management, contract administration, project control and HSE, with reference to international contracting and business practices.

This handbook on the commissioning of all process plants, large and small, has been fully updated and expanded. The aim of the text is to provide the non-specialist with advice on how to set about the problem of commissioning either a new plant or a modification. Some aspects of decommissioning are also included. The section on legislation has been expanded and updated to cover all areas of safety, health and environment.

Industrial Process Plant Construction Estimating and Man-Hour Analysis focuses on industrial process plants and enables the estimator to apply statistical applications, estimate data tables, and estimate sheets to use methods for collecting, organizing, summarizing, presenting, and analyzing historical man-hour data. The book begins with an introduction devoted to labor, productivity measurement, collection of historical data, verification of data, estimating methods, and factors affecting construction labor productivity and impacts of data. It goes on to explore construction statistics and mathematical spreadsheets, followed by detailed scopes of work ranging from coal-fired power plants to oil refineries and solar plants, among others. Man-hour schedules based on historical data collected from past installations in industrial process plants are also included as well as a detailed glossary, Excel and mathematical formulas, area and volume formulas, metric/standard conversions, and boiler man-hour tables. Industrial Process Plant Construction Estimating and Man-Hour Analysis aids industrial project managers, estimators, and engineers with the level of detail and practical utility for today’s industrial operations and is an ideal resource for those involved in engineering, technology, or construction estimation. Identify quantity differences with the comparison method and eliminate impacts between proposed and previously installed equipment Understand how to implement statistical and estimating methods, scopes of work, man-hour tables and estimate sheets to produce direct craft man-hour estimates, RFPs, and field change orders Set up and utilize Excel templates to automate statistical functions that will perform mathematical applications key to process plant construction

Industrial Process Plant Construction Estimating and Man-Hour Analysis focuses on industrial process plants and enables the estimator to apply statistical applications, estimate data tables, and estimate sheets to use methods for collecting, organizing, summarizing, presenting, and analyzing historical man-hour data. The book begins with an introduction devoted to labor, productivity measurement, collection of historical data, verification of data, estimating methods, and factors affecting construction labor productivity and impacts of data. It goes on to explore construction statistics and mathematical spreadsheets, followed by detailed scopes of work ranging from coal-fired power plants to oil refineries and solar plants, among others. Man-hour schedules based on historical data collected from past installations in industrial process plants are also included as well as a detailed glossary, Excel and mathematical formulas, area and volume formulas, metric/standard conversions, and boiler man-hour tables. Industrial Process Plant Construction Estimating and Man-Hour Analysis aids industrial project managers, estimators, and engineers with the level of detail and practical utility for today's industrial operations and is an ideal resource for those involved in engineering, technology, or construction estimation. Identify quantity differences with the comparison method and eliminate impacts between proposed and previously installed equipment Understand how to implement statistical and estimating methods, scopes of work, man-hour tables and estimate sheets to produce direct craft man-hour estimates, RFPs, and field change orders Set up and utilize Excel templates to automate statistical functions that will perform mathematical applications key to process plant construction

If you want a book that you can use on almost a daily basis in a construction-contractor organization, then this is it. Whether you work as managing director, business development manager, chief proposal manager, lead engineer & estimator, the operation manager, project control manager, cost control engineers, procurement manager, information technology, HR or even in a corporate advisory role, the skills outlined in this book can increase your role & effectiveness & create an impact from the first reading. This book gives a practical understanding of the skills required to become a high-performance manager in your area of expertise. It will help you to: - win high-value construction contracts & execute it with effective control to ensure predicted profit or more - develop stronger, more productive working relationship with customers - market your services, diversify effectively and build powerful networks - secure greater satisfied customer base and prequalify with new customers - work effectively in less formal and hierarchical ways on projects & initiatives - enhance your own worth & value in the organization

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

Process Plant Layout, Second Edition, explains the methodologies used by professional designers to layout process equipment and pipework, plots, plants, sites, and their corresponding environmental features in a safe, economical way. It is supported with tables of separation distances, rules of thumb, and codes of practice and standards. The book includes more than seventy-five case studies on what can go wrong when layout is not properly considered. Sean Moran has thoroughly rewritten and re-illustrated this book to reflect advances in technology and best practices, for example, changes in how designers balance layout density with cost, operability, and safety considerations. The content covers the ‘why’ underlying process design company guidelines, providing a firm foundation for career growth for process design engineers. It is ideal for process plant designers in contracting, consultancy, and for operating companies at all stages of their careers, and is also of importance for operations and maintenance staff involved with a new build, guiding them through plot plan reviews. Based on interviews with over 200 professional process plant designers Explains multiple plant layout methodologies used by professional process engineers, piping engineers, and process architects Includes advice on how to choose and use the latest CAD tools for plant layout Ensures that all methodologies integrate to comply with worldwide risk management legislation