Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
IN BRIEF
PILOT VERSUS
COMMERCIAL SCALE
ESTIMATING METHODS
REVIEWING THE
ESTIMATE
CONTEMPLATING
CONTINGENCY
CLOSING THOUGHTS
FIGURE 1. Instrumentation is one area in pilot plants that typically does not scale up very small tanks likely still have instrumentation requirements similar to 15,000-gal tanks in a commercial plant
CHEMICAL ENGINEERING
DECEMBER 2016
OKTALINE ATEX
Magnetically coupled
Roots pump combines
a magnetic coupling with
category 2 or 3 explosion
protection
CHEMICAL ENGINEERING
WWW.CHEMENGONLINE.COM
DECEMBER 2016
39
40
WWW.CHEMENGONLINE.COM
DECEMBER 2016
CHEMICAL ENGINEERING
Engineering
3 weeks
% of time
10%
80%
25%
5%
0%
0%
5%
2%
5%
10%
10%
0%
$37,136
Construction
12 weeks
% of time
50%
30%
50%
100%
100%
75%
0%
5%
2%
5%
5%
2%
$265,530
WWW.CHEMENGONLINE.COM
41
DECEMBER
2016
Circle 19 on
p. 202 or go to adlinks.chemengonline.com/61502-19
42
Estimating methods
With all of these differences, it should be
clear that estimating methods that are
used for commercial facilities normally
do not do a good job of estimating pilotplant construction costs. For example,
one of the most trusted methods used
for early estimating of commercial plants
WWW.CHEMENGONLINE.COM
DECEMBER 2016
WWW.CHEMENGONLINE.COM
DECEMBER 2016
43
CHEMICAL ENGINEERING
WWW.CHEMENGONLINE.COM
DECEMBER 2016
Contemplating contingency
In the authors experience, contingency
has always meant money that is estimated to account for the unexpected
problems that come up on a project. It
is a project-execution fund, plain and
simple. An example is if you dig up an
underground line that you expected to
tie into and find that it is partially damaged and a section needs to be replaced
to allow the tie-in. This is a replacement
Nol-Tec Systems
your partner in handling success
TM
Air Assist
sales@nol-tec.com
www.nol-tec.com
WWW.CHEMENGONLINE.COM
DECEMBER 2016
45
CHEMICAL ENGINEERING
Closing thoughts
Pilot plant work is unique, not only in its
scale, but also in its work processes and
nuances. Cost estimating for pilot plants
is but one of these unique aspects. While
the chemical process industries have
worked with EPC contractors to develop
common tools, protocols and language
to manage projects, the world of R&D
is quite different. Not only is each project very different in its objectives and its
scope, but there are few set protocols
and standard methods for activities like
cost estimating.
But while each company may do
things a little differently, the important thing is to recognize that they are
unique facilities, and the tools required
to do the job are different than those
used in a commercial setting. That includes the intellectual tools, such as
cost-estimating methods. Once you
have figured out the differences, and as
long as you approach the estimate in a
logical and thorough manner, you should
end up with a reliable estimate and a
manageable budget.
Edited by Mary Page Bailey
Author
Rob Nunley joined MATRIC (Mid-Atlantic Technology, Research and Innovation
Center; 1740 Union Carbide Drive,
South Charleston, WV 25303; Phone:
(304) 720-6707; Email: rob.nunley@
matricinnovates.com; Website: www.
matricinnovates.com) in 2013 as pilot
plant programs manager. In this capacity, he oversees the construction and
operations of pilot plants in MATRICs
facilities and the build-out of skid units for shipment to customer locations. Nunley has 24 years of engineering experience in the chemical industry with a broad background spanning multiple functions, including process engineering,
conceptual process design, new products development,
manufacturing and project management. In prior positions,
he supervised plant operations, production and raw-material
planning and has extensive startup, troubleshooting and crisis-management experience. Nunley has served as lead engineer and project manager on projects ranging from $2 to
30 million and has served lead roles on conceptual designs
including a $2-billion grassroots chemical complex. He
earned his B.S.Ch.E. from the University of Rochester and his
M.S. in Engineering Science from Marshall University.
WWW.CHEMENGONLINE.COM
DECEMBER 2016