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Part 2
H
Anna Farokhi istorically,
and Charlie Lyda new capital
Ruor projects and
facility up-
IN BRIEF grades in the chemi
cal process industries
DESIGN PHASE
(CPI) were designed
EQUIPMENT with a primary focus
PRESERVATION PLANS on operations. As the
MODULE-YARD CPI have worked to re
EXECUTION PLANS duce the total installed
cost (TIC) of projects,
SITE-SPECIFIC many engineering, i
EXECUTION PLANS
procurement and con
struction (EPC) firms
have begun to incor FIGURE 1. Many large capital projects in the CPI put great focus on decreasing overall costs
porate modular de and compressing plot footprints, but they must do so while still considering the proper con
sign and fabrication struction execution sequence
methodologies into their project-execution commissioning and startup of the facility are
strategy. The design teams spend consid not easily understood or quantified.
erable time finalizing the site plot plans. In addition to modular designs, projects
The objectives here are to compress the continue to transition from the typical ex
overall plot footprint and reduce piping ecution model - consisting of mechanical
and electrical system quantities, while still completion, commissioning and startup —
considering the construction execution to a parallel-activity model where power,
sequence (Figure 1). utility and process systems are commis
As module-design techniques continue to sioned and placed into service while con
mature, piping-system lengths are reduced,struction continues in other facility areas
the density of the operating equipment is and systems.
often compressed, electrical system quanti Especially in this type of project-execu
ties are minimized and the total cost of contion environment, early involvement of the
struction is reduced. Recent data suggest commissioning and startup team members
that with modular designs, piping and elec is critical. Involvement of the team during
trical systems quantities can be reduced by module design reviews and the develop
25 to 30% when compared to traditionally ment of equipment preservation plans,
designed facilities. module-yard execution plans, site commis
While the cost of design, materials, con sioning and startup execution plans and
struction labor and logistics can be easily performance testing plans leads to safer
developed and compared against histori execution, a reduced project TIC and op
cal data to illustrate the TIC benefit of new timized project schedule durations. This ar
techniques, the potential benefits to the ticle describes several areas where early in-
)
lation on site. The comprehensive
equipment-preservation plan is
often a combination of EPC and cli
ent quality program requirements,
coupled with the equipment suppli
ers’ recommendations. As supplier
information is received, the docu
ments should be reviewed with a
focus on preservation and any re
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quirements recorded in the com
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pletions software. It is advisable to
include any required forms in the
vendor purchase orders that out www.gemu.com
line and record preservation activi
ties. This requirement saves count
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7
startup source (for instance, an auxiliary
boiler or heat-recovery steam generator)
may not have the capacity required to
meet the downstream requirements for iii
cleanliness criteria. As cleaning plans
are finalized, the teams consider tempo
rary sources for the steam supply, the
required fuel-supply connections, steam
system connections and temporary ■*.
exhaust points.
Building on the activities performed
in the module yards, detailed proce gether to provide great benefits in terms figure 4. a detailed pipe-system ciean-
dures are developed to finalize the of more-effective plans and designs. Ing strategy must be developed for the
module yard
pre-commissioning activities for the The opportunity to influence a project’s
electrical systems, instrumentation and safety, productivity, cost and schedule is
controls systems and equipment lube-oilat its greatest during the design phase.
flushing activities. The commissioning and startup teams’
System- and unit-specific startup early involvement enables the develop
procedures are developed based on ment of a comprehensive set of testing
the manufacturer or licensor’s instruc activities that span the project lifecycle,
tions, process system descriptions and commencing at the module yards and
major-equipment supplier manuals. As completing at the site in support of a
sembling this information prior to mobi successful facility startup. Conducting
lization ensures that a comprehensive early design reviews with a commission
startup program is in place and that the ing and startup focus reduces total costs
appropriate reviews are performed. Thesignificantly and yields a more predict
procedures include sections outlining able outcome in the field. ■
the interface requirements to other units Edited by Mary Page Bailey
within the facility, special drying and
refractory-curing processes, temporary Authors
feedstock requirements (if any), initial Afsaneh (Anna) Farokhl is a commis
valve alignment tables, initial operating sioning manager with Fluor Corp.
(1 Fluor Daniel Dr. Sugarland, TX
setpoints and a summary of equipment 3» 77478: afsaneh.tarokhi@tluor.com),
operating alarms. currently supporting a government proj
Similar to the process-system commis ect in Virginia. She also supports the
functional organization, overseeing
sioning procedures, electrical-system en global commissioning operations and
ergization plans are developed to ensure execution. With 12 years of industry ex
the proper pre-energization testing is per perience. she has held a diverse range
of office and field assignments, both domestic and interna
formed, all safety precautions are in place tional. Farokhi was named to Engineering News-Record's
and the correct energization sequence (ENR) first national Top 20 Under 40 in 2017. a list that rec
ognizes the construction industry's top young professionals.
is followed.
Charlie Lyda currently serves as vice
The electrical and process system president of commissioning and turn
startup procedures are developed to over at Fluor Corp. (100 Fluor Daniel
align with the project-specific lockout/ Or., Greenville. S.C. 29607; chades.
lyda@fluor.com). in this role, he is re
tagout (LOTO) procedures, electrical sponsible for pre-commissioning, com
arc-flash safety procedures, system missioning, startup and turnover for
boundary tagging and blinding proce Fluor's projects across all business
lines. Lyda has more than 30 years of
dures and established HSE practices experience in commissioning, startup,
and procedures. operations and maintenance of electric power-generation,
All of these individual pieces come to- petrochemical and chemical manufacturing facilities.