Project Best Practices

Project Best Practices Michael S. Forsthoffer, in Forsthoffer's More Best Practices for Rotating Equipment, 2017 Benchmarks This Best Practice has been used by Forsthoffer Associates, Inc. since 1990 and for Projects in all Industrial Plant Applications including but not limited to: • Ammonia Syngas and Refrigeration Compressor Trains • Methanol Syngas and Circulator Compressor Trains • LNG—PRC, ERC, and Mixed Refrig. Compressor Trains • Ethylene Plant—PGC (CGC), Propane, and Ethylene Refrig. Compressor Trains This approach has resulted in machinery being selected to proper specs with minimal scheduling delays at minimum capital cost. B.P. 1.7: Think “Outside the Flanges" when preparing datasheets. Include process and system effect details into the datasheets The vendors are trying to design the equipment to meet all of the user’s needs; however they do not fully know the process and the objectives of the end user. If the vendor knows fully how the process is designed and what issues could occur during the life of the plant they may be able to incorporate provisions into the design of the equipment in order to keep it operating at maximum efficiency and reliability. Discuss the process flow diagram (PFD) and piping and instrumentation diagram/drawing (P&ID) for each process with experienced Process Engineers from the Process Licensors, Project Team and/or Plant Process Engineers and Operators. Define, with the concurrence of the experienced Process Engineers and Operators the potential upset and unusual process conditions. Be sure that all upset and unusual process conditions are defined on the appropriate equipment data sheets. Require that an experienced Process Engineer and Operator be part of the Machinery Project Team and attend all planning sessions, specification and data sheet reviews, as well as all vendor meetings during the Pre-Selection, Design, and Test Phases. L.L. 1.7: It is the writer’s experience that approximately 80% of Machinery Failure Root Causes are due to process variations not anticipated in the design phase Detailed Root Cause Failure Analysis (RCFA’s) show that the majority of Root Causes of Failure lie in unanticipated process condition changes. Failure to incorporate these upset and unusual conditions on the appropriate equipment Data Sheets can: • Extend Project Schedule by requiring Machinery Re-Design • Result in significant cost adders for Machinery Re-Design • Reduce Machinery Safety and Reliability • Extend Plant Start-Up

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