2A1 Chapter 4 Plant Design and Installation

2nd Class Power Engineering

What must be followed when designing and building a new plant?

Codes and standards specific to the location of the new plant.

What is required for a plant installed in Canada?

It must meet the standards and codes adopted by the province.

What are some engineering disciplines that have specific codes and standards?

Environmental, civil, chemical, mechanical, and electrical.

What types of permits must companies obtain before construction?

Work permits related to electrical, plumbing, building, fire, and gas codes.

What are the benefits of obtaining a construction permit?

Ensures conformity to construction and safety standards and allows for inspections by certified codes officers.

What is CSA B51-97?

Boiler, Pressure Vessel, and Pressure Piping Code.

What does ASME Section I cover?

Requirements for the field assembly of power boilers and external piping.

ASTM, NFPA, UL, FM, and ANSI are _____

Research and Testing Organizations

ASHRAE, ASCE, and ASME are _____.

Professional Associations

APA, SMACNA, and ACI are _____.

Trade Associations

What is the purpose of a feasibility study in plant construction?

To evaluate the feasibility, size, and cost of the plant.

What does a feasibility study primarily emphasize?

Economics and the economic viability of the plant.

What costs are included in a feasibility study?

Building costs, operation, maintenance, depreciation, insurance, interest, and taxes.

What environmental issues must be addressed in a feasibility study?

Potential for air, water, and ground pollution, and unacceptable noise levels.

What happens after a feasibility study is accepted?

Detailed design and specifications are developed for the plant.

What does detailed design involve?

Finalizing the plant design, including plot plans and specifications for construction.

What types of choices must be made during detailed design?

Type of fuel, production process, auxiliary equipment, instrumentation, control, and power supply.

What is the role of the engineering company in plant design?

To finalize the design and produce drawings and specifications for construction.

What is the purpose of detailed engineering?

To provide the information and specifications required to construct the plant.

What is ASME B31.1?

Power Piping, which contains requirements for the installation of boiler external piping.

What does the National Fire Protection Association (NFPA) 58 cover?

Liquefied Petroleum Gas Code.

What is the significance of the Manufacturing Standardization Society (MSS)?

They produce standards for piping, valves, and fittings.

What is ASTM?

American Society for Testing and Materials, involved in testing standards.

What does ASHRAE stand for?

American Society of Heating, Refrigerating and Air Conditioning Engineers.

What does the term 'detailed design' refer to in plant construction?

The finalization of plant design including all necessary specifications and drawings.

What must be included in the operating and maintenance budget?

Costs related to operation, maintenance, and other associated expenses.

What is the importance of local standards in plant design?

They address traffic, noise, odour, and appearance issues.

What is the purpose of the Canadian Standards Association (CSA)?

To establish codes and standards for various engineering disciplines.

What is the role of professional associations in plant design?

To provide guidelines and standards that influence design and construction practices.

What is the first step in the design of a new plant?

The feasibility study.

What do drawings and specifications provide for construction companies?

The amount of detail required to create competitive bids.

Why is it cost-effective to incorporate changes during the design stage?

Because it is cheaper to make changes before construction begins.

What do drawings represent in the context of plant design?

A graphic representation of the plant layout.

What do specification sheets provide in plant design?

Details of the components of the plant.

Design pressure and temperature, operating temperature and pressure, and quality of materials are included in a _____.

Piping specification

What is the purpose of the engineering study?

To determine whether the plant should be constructed and if it is economically feasible.

What factors are considered in the engineering study?

Size of the plant, demand for product, government regulations, and economic alternatives.

What does the detailed design process build upon?

The work accomplished in the engineering study.

What types of drawings are included in the detailed design?

P&IDs, construction drawings, and process flow diagrams.

What is the role of the plant owner during the design process?

To stay involved and specify any additions or options to be incorporated into the design.

What is a diagram showing the overall plant process streams?

Process Flow Diagram (PFD)

What happens to existing specifications when new equipment is added to a plant?

They are used if possible, but must be updated if new specifications differ.

What drawing contains piping line numbers and refers to the specification number for details?

Process and Instrumentation Drawing (P&ID)

What is the purpose of detailed specifications in plant design?

To contain all details needed for purchasing materials and for plant construction.

What is the benefit of using Computer Assisted Drafting (CAD) in plant design?

It allows for detailed and precise drawings and specifications.

What is included in the engineering study report?

Capital required, operating costs, fixed costs, and recommendations.

What is the purpose of a scale model in plant design?

To determine equipment placement and detect interferences.

What is the role of automation in new plant installations?

To increase efficiency and reduce the need for personnel.

What must be done if new piping has different specifications from existing piping?

The specification sheets must be updated.

What is the main goal of the detailed design phase?

To produce the drawings and specifications needed for construction.

What does the engineering study assess regarding government regulations?

The influence of environmental impacts on plant construction.

What types of economic alternatives might be considered in the engineering study?

Different plant locations, output sizes, or fuel types.

Who finalizes the design of the plant?

The engineering company

What is a key consideration when choosing the mode of operation for a plant?

Whether the plant is run in a steady state mode, base loaded, or for peak loads.

What is the significance of instrumentation in plant design?

It affects the level of automation and efficiency.

What are the main components involved in plant construction?

Piping, electrical systems, civil works (buildings, steelwork, roads, underground piping), instrumentation, and control systems.

What are performance specifications used for?

Specifying outputs of pumps, fans, turbines, motors, and electric generators.

What is the role of the primary or general contractor in plant construction?

Oversees the construction of the plant.

What follows the detailed design phase in plant construction?

The bidding or negotiation phase.

What is included in the bid documents during the bidding phase?

Timeline, forms of payment, and other required details.

What happens during the construction phase to the engineering staff?

They change their focus to contract administration and quality assurance.

What is the basic order of work during the construction phase?

Site grading, excavation, laying underground piping, electrical supply installation, placing equipment, erecting buildings, placing large vessels, installing piping, installing small pumps, and insulating.

What is pre-commissioning?

Steps completed before the commissioning or startup of the plant, including air blowing, hydrostatic testing, and test running pumps.

What does commissioning involve?

The startup process of a new plant, done in systems, following manufacturer recommendations.

Who is responsible for obtaining permits, conducting feasibility studies, determining location, obtaining funds, and staffing the facility?

Owner

Who is responsible for detailed engineering, preparing drawings, vendor catalogues, and construction documents?

Designers

What tasks do design engineers perform?

Prepare detailed engineering designs, drawings, specifications, and evaluate bids for materials and construction.

Who has the overall responsibility for building the plant, including managing subcontracted work?

General construction contractor

What is the purpose of hydrostatic testing?

To test for leaks in flanges and piping.

What is the significance of the bidding review process?

To analyze competing bids to select the winning bid, usually the lowest cost.

What is involved in the startup process of a new plant?

Commissioning systems in a specific order, ensuring adherence to temperature and pressure limits.

What is the importance of quality assurance during construction?

Ensures that the construction adheres to specifications and resolves design changes.

What activities are included in the pre-commissioning schedule?

Air blowing, checking control loops, hydrostatic testing, and test running pumps.

How can change orders affect the price of a project?

Changes in design increase project costs and require re-engineering and modifications to the drawings.

What is the first step in the commissioning process?

Starting with utilities and plant offsites.

What is the significance of the feasibility study?

Determines the viability of constructing and operating the new facility.

What are the responsibilities of the owner regarding staff training?

Ensure all staff become familiar with the new facility and management system.

What is the purpose of using computer-aided drafting in plant design?

To produce three-dimensional images of the plant.

What is the role of the design engineering company?

To handle most of the detailed engineering for the plant.

What are the steps involved in the startup of main processes?

Starting in steps, sending product to storage, and slowly raising plant rates.

What is the primary responsibility of a general contractor?

To handle purchasing materials, supervising tradespeople, and scheduling the overall project.

Why are subcontractors hired by general contractors?

To perform specialized work more economically than the general contractor.

Cooling tower construction, building construction (warehouses, control centers), and installation of specialized systems are the types of jobs often contracted out to _____.

Subcontractors

What is the role of quality control (QC) personnel during plant construction?

Shop inspections, pressure testing, and verifying compliance with design specifications.

What basic QC tasks are usually conducted by subcontractors?

X-raying of piping and steelwork.

What is the main task of operations staff during the construction phase?

To learn about the new plant processes and systems before startup.

What is a punch list in the context of plant construction?

A list of construction deficiencies in a piping system.

What is the purpose of line blowing in piping systems?

To clean debris out of a piping system.

What is leak testing in piping systems?

A process to detect leaks by applying a small gas pressure to the system.

What is the project arrangement where the owner gets a scope definition with basic engineering partly complete and the cost of the project cannot be finalized until all changes in scope have been completed?

Design - Bid - Build

What is the project arrangement where basic engineering about 10% complete and an engineering company is selected to do the detailed design, procurement, and construction?

Reimbursable Engineering Procurement Construction (EPC)

In the Reimbursable Engineering Procurement Construction (EPC) arrangement, how is the engineering company paid?

They are paid the actual cost plus a fee for each project phase. The total cost of the project is not known until all phases of the project are complete.

What is the type of arrangement where the basic design engineering is about 20% complete, then the owner selects a company to complete the detailed design, order the equipment, and construct the plant?

Design - Build

What arrangement completes the entire project based on a final, lump sum payment?

Design – Build

What is an arrangement where basic engineering is about 20% or more complete and each phase is put out for bids on a lump sum basis, with a contractor selected for each phase of the project?

Lump Sum EPC

What is the importance of scheduling in construction field administration?

To ensure timely completion of the project and effective monitoring of construction progress.

What is the role of the resident manager on a construction site?

To act as the plant manager overseeing the construction activities.

What types of personnel are included in the construction group on a project site?

Supervisors, safety personnel, and construction-related staff.

What is the significance of effective communication among project personnel?

To ensure timely and cost-effective completion of the project.

What does ASME stand for in the context of plant design and construction?

American Society of Mechanical Engineers.