Cost Effective Pilot Plant Design and Construction

R P Palluzi
ExxonMobil Research & Engineering Co CSR Research Support Services Clinton, NJ

Background
PPLE is ExxonMobils center of excellence for pilot plant and laboratory work
Design Construction Operation Start-up Upgrades and modifications Safety Relocations Consulting Standards

Background (contd)
Provide services to ExxonMobil and its affiliates worldwide
From consulting to projects ($10,000-$65,000,000) New construction, relocations, upgrades, safety reviews, start-ups, operation problems, etc.

Located in Clinton Township facility

850,00 SF modern research facility Relocated from older Linden facility in 1981 Specialty shops, engineering facilities and support areas

Challenges
Increased global competition demands more cost effective and faster research effort Costs and time to design, construct and start-up a pilot plant can be significant Reduced resources available due to downsizing

New approaches required

EMREs Response To These Challenges

Modular design and construction PC/PLC based control systems Pilot plant specific standards and designs CAD/CAE Improved S/H/E planning Improved start-up planning and techniques

Modular Construction
Palletization of all new units
Allows efficient shop construction Reduces relocation, modification and demolition costs (life cycle costs)

Specialized construction shop

20+% savings over field construction Improved safety Improved construction quality

Standardized designs
Reduces design effort Significant reduction in start-up effort (10+%)

Modular Construction (contd)

Standardized assemblies
Reduces construction time Promotes savings through bulk procurement Reduced troubleshooting time Reduced risk of failure to perform

Experienced staff
Engineering, design and craft Familiarity promotes efficiency Allows delegation of many tasks to lower, less expensive resource

Modular Construction (contd)

Improved wiring techniques
Junction boxes on all pallets to allow relocation and facilitate troubleshooting Multiconductor cable Spare wiring as part of initial construction Extensive use of lay in duct or cable tray to facilitate initial wiring and modifications

Improved utility piping

Prefabricated manifolds Spare taps Multi-tubing bundles where appropriate

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Improved Control Systems

Computer control of all new units
Operational efficiencies far outweigh initial costs Reduced operating personnel Improved product quality (product and/or data)

Personal computers (PC) or programmable logic controller (PLC) based

Standalone systems increase reliability Inexpensive to install, modify and expand Final selection usually driven by size

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Improved Control Systems (contd)

Cost effective integration/isolation of control and safety systems
Standard: PC for control, PLC for safety interlocks Alternate: high-end PLC for control, low end PLC for interlocks Ensures safest cost effective separation No recorded failure in 20 years Promotes efficient operation Minimizes operator attention to routine tasks Promotes efficient data collection, reduction and analysis Allows integration of other data or transmission of unit data

Specialized programming

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Improved Control Systems (contd)

Unattended operation incorporated into all units
50+% decrease in operating staff since 1983 Significantly improved product quality (70% in one case!) Allows further staffing reductions at low cost later

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Pilot Plant Specific Designs

Pilot plant specific standards speed design process
Reduces design effort Encourages building block approach Ensures tested, trouble-free installations Reduces start-up time (50% since 1980)

Standardized assemblies speed design and construction

Decreases construction time (10% since 1980) Reduced potential for error and rework

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Pilot Plant Specific Designs (contd)

Assembly line construction of many common elements
Relief valve manifolds Gas feed systems Utility headers Instrument cabinets

Pilot plant specific construction management

Reduces costs Improves quality control through better focus

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CAD/CAE
Heavy investment in automated design State of the art CAD system decreases design time
Automated bill of materials Standard drawing assemblies Ability to cut and paste from thousands of other units

On-line estimating system

Improved accuracy with reduced effort Better historical trending Improved validation

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CAD/CAE (contd)
Numerous on-line design programs
Many pilot plant specific Decreases expensive engineering effort

Electronic transfer of information

Eliminates wasteful duplication of information Ensures single source for all info reducing error

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Improved S/H/E Planning

Conceptual safety reviews identify issues earlier
Allows time to effectively address from start of design Improves evaluation of alternatives Often results in process or program shifts to avoid costly or timeconsuming issues

Pilot plant specific risk assessments

Improves realism Eliminates inappropriate concerns Reduces effort

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Improved S/H/E Planning (contd)

Pilot plant specific standards
Reduces review effort Ensures acceptable design Reflects actual operating experience

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Improved Start-Up Planning and Techniques

Start-up technical review conducted before finalizing design
Allows identification of potential problem areas early enough to allow resolution Allows obvious problems to be corrected before construction Captures 70% of the obvious problems Utilizes experienced start-up team

Start-up planning initiated shortly after unit approval

Ensures start-up issues are addressed with adequate time for resolution

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Improved Start-Up Planning and Techniques (contd)

Start-up sequence for all units
Sequential listing of all start-up tasks Includes estimate of resources and effort Allows realistic start-up estimate and schedule Allows identification of resource, skill area and/or specific issues early enough to be worked Flushing carts Leak testing equipment Troubleshooting equipment Calibration shop

Specialized start-up equipment and facilities

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Abstracted from larger start-up sequence

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Cost Performance
Costs Per Equivalent Unit Pilot Plants Laboratories

Cost/ Equivalent Unit

1981-84

1986-87

1993-94

1992-94

1994-96

2000-2001

1999-2001

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Schedule Performance
Equivalent Units Per Unit Time

1999-2001

2000-2001

1994-96

1993-94

1986-87

1981-84

Time Per Equiv Unit

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