Plant design & engineering phases
Plant design & Engineering phases:
If you are building or scaling up an industrial plant, the process engineering & process management company adds value to your industrial plant design project by combining plant and unit operation knowledge, with experience in a wide variety of industries and applications. Combining experience in industrial plant design with extensive knowledge of your process, the plant design engineering company should develop a solution that meets your budget and timeline.
Panorama’s engineering and fabrication expertise is coupled with a unique modular approach. From equipment selection to construction management, coordinating the entire scope of the project is a complex process in which we excel. From piping specifications on every P&ID to managing subcontractors, Panorama’s highly experienced engineers & leadership ensure every detail meets or exceeds your needs.
Panorama’s modular design approach saves an average of 24% time compared to traditional construction schedules. Your plant will make product sooner, and overall costs will be reduced.
STEP 1: Front-end Engineering for Industrial Plant Design
To initiate, the plant design engineers will fully extract the project scope, discuss potential challenges, and create a comprehensive project schedule up-front. This is a critical first step in developing your plant.
Most companies provide a basic quotation that doesn’t ensure project success. An ideal plant design & engineering company believes engineering detail is most important in the beginning of the project. Spending essential time up-front to provide accurate preliminary pricing and a design you can be confident with is the first priority of a industrial plant design & engineering company.
Typically, companies offer three levels of front-end engineering, with each step requiring more engineering but also returning increasingly accurate numbers. Rough Order of Magnitude (ROM) Quotes include:
1. Basic project scope
2. Boundary limits
3. +/- 50% ROM quote
2. Refined Quotation’s
1. +/- 15-5% estimate
2. Project timeline
3. Basic P&ID’s
4. Equipment, instrument, and valve list based on budgetary quotes
3. Fixed Bid Quotes
1. A firm price to deliver the project (fixed bid price)
2. Project timeline
3. Basic P&ID’s
4. Equipment, instrumentation and valve list based on specific details
5. Quotation peer review
6. Technical review
7. Additional customer specified documents
STEP 2: Detailed Design
The first part of detailed design includes a tightening of the numbers and scope of your project. One fixed bid price has been reached, the following begins:
- Re-evaluation for further time/cost savings
- Set key project milestones and dates
Finalize modular industrial plant design including:
- Process automation
- Mechanical and structural design
- Footing details
- Shipment constraint planning
- 2D and 3D models
- CAD system development
- Any process modeling that must be completed (ex. ASPEN HYSYS)
- Additional drawing development
- Auxiliary views
- Detailed elevation drawings
- Detailed plan drawings
- General equipment and arrangement drawings
- Isometric drawings
STEP 3: Equipment Procurement for Industrial Plant Design
Once the plant design engineers complete detailed engineering, the equipment is ordered for your project. Equipment with long lead times, or key to project milestones, is ordered first. Equipment is selected upon lowest total lifetime cost, as opposed to lowest upfront cost.
SIDE-STEP: Process Safety & HAZOP Studies
If your process requires any safety study, (HAZOP for instance) they will be completed during design. The timing depends on your availability and the information needed to complete the design.
Step 4: Industrial Plant Construction
Industrial plant construction happens in a state-of-the-art fabrication plant. A compressed build timeline, higher quality construction and lower total modular fabrication costs are direct outcomes of the controlled, production-style environment. Parallel field upgrades happen simultaneously to industrial plant construction without interfering with each other, since plants should be constructed in shop as modules while site-upgrades happen at your manufacturing facility.
Step 5: Installation and Commissioning
Once off-site industrial plant construction is complete, modules are fully FAT tested and then shipped to your site for installation. Process experts install your new production plant and make sure it is fully integrated, both mechanically and electrically, into your facility. Process hookups, functional testing and the punch-list are completed and resolved. A full fledged training to your plant operators on the full system is provided.