Case study

Case 1: New plant planning

When considering the construction of a new plant, the customer had already selected the process equipment, but did not know how to proceed with the rest of the process and was groping around, asking each equipment manufacturer.

Therefore, we worked together with the customer to organise the information.

Embodiment of plant operational plans.

As the targets for annual production volume, potential material suppliers and planned sales destinations seemed to have been decided, the following information was organised and the figures were concretely built up.

• Number of operating days per year. Considering scheduled maintenance shutdowns and operations during consecutive holidays.
• Target production volumes per month, week and day.
• Number of workers required for equipment operation.
• Number of workers required for indirect operations.
• Storage space for raw materials and products, transport methods and number of days for dispatch
• Storage space for equipment spares, consumables, etc.

Layout design

In parallel with the realisation of the plant operation plan, the specifications for the layout design were also finalised.
The following items were checked on a case-by-case basis, and the layout was proposed and gradually brought closer to the ideal form.

• Does the equipment layout follow the process and does it not cause unnecessary travel or piping?
• Are utility piping and electrical and instrumentation cables the shortest possible distances?
• Are working spaces and equipment maintenance spaces secured?
• Considering the number of days required for equipment procurement, will the project start date be delayed due to construction date adjustments, etc.

Specification document preparation

In the specifications submitted to the equipment manufacturers, some items were not clear as to which party was responsible for what and to what extent, and there was a possibility of increased costs and delays in delivery due to additional specifications, so the purchase specifications were redrafted.

• Project overview. Objectives, location, deadlines, etc.
• Equipment requirement specifications. Processing capacity, number of units, whether or not ancillary works are required, etc.
• Scope of responsibility. Documentation, interim inspection, transport, installation, ancillary works, etc.
• Warranty conditions, other precautions, etc.

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