Paul Dragovic - Momentum Engineering - Efficient Engineering of Compressor Stations
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Paul Dragovic delivered the presentation at 2014 Gas Compressor Stations Conference. ...

Paul Dragovic delivered the presentation at 2014 Gas Compressor Stations Conference.

The Gas Compressor Stations Conference is the only conference specifically dedicated to the design, build and maintenance of gas compressor stations.

For more information about the event, please visit: http://www.informa.com.au/gascompressors14

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Paul Dragovic - Momentum Engineering - Efficient Engineering of Compressor Stations Presentation Transcript

  • 1. www.momeng.com.au
  • 2. Efficient Engineering of Compressor Stations Gas Compressor Stations Conference 29-30th April 2014, Brisbane, Queensland Presented by Paul Dragovic – General Manager
  • 3. Outline • Overall Project Drivers • Basis of Design and Layout Considerations • Phases of Design and Value Engineering • Key Engineering Schedule Drivers • Importance of Experience
  • 4. Overall Project Drivers • Safety – Constructability – Operability – Maintainability • Quality – Design life – Material selection – Station “up-time” Overall Efficiency! • Cost – Fit for purpose – Easy to construct • Schedule – Customer start-up
  • 5. BOD and Layout • Site accessibility – in particular remote locations • Environment - soil conditions, weather, noise limits, etc • Regulatory requirements • Process requirements – gas specifications (inlet and outlet) • Equipment, piping, instrument and cabling specifications • Power supply – main and back-up • Process control philosophy (manned v unmanned) • Operating philosophy, isolation & blowdown philosophy • Availability and Reliability • Constructability • Operations and Maintenance Access (routine and shutdown) • Equipment Separation – Fire and Explosion Risk • Emergency Response - Escape • Design Life, Future Expansion, etc • Stress and Vibration Each site = unique conditions!
  • 6. Project Phases Identify (Feasibility) Concept Select Define (FEED) Execute I (Detail Des.) Execute II (Constr’n) Operate • Note – FEL is important for large projects to ensure the correct concept is selected before commencing the detail design. • May deliver any or all of the following phases of a project. Note total installed cost (TIC) estimate class / accuracy at the end of each phase Class 1 (+/-50%) Class 2 (+/-30%) Class 3 (+/-15%) Class 4 (+/-10%) Front End Loading (FEL)
  • 7. Front End Loading - FEL Feasibility Concept FEED Detail Design & Fabrication Operate FRONT END LOADING Value gained Value lost Cost to implement a change Cost saving / value achieved
  • 8. Value Engineering • Part of Front End Loading (FEL) • Always important to spend money wisely, however do not “penny pinch” in early phases. • Use of Value Improvement Practices (VIPs): – Technology and equipment selection – Process simplification, design to capacity – Standard design, avoid customisation – Constructability – Conservation of energy – Reliability-Availability-Maintainability (RAM)
  • 9. Project Size or Risk • Note 1 – FID = Final Investment Decision • Typical gate approvals based on project size / risk Small Projects (low cost or risk) Medium Size Projects (med. cost or risk) Large Projects (high cost or risk) Feasibility through to Detail Design Feasibility and Concept Identify (Feasibility) Concept Select (Pre-FEED) FEED and Detail Design Define (FEED) Execute I (Detail Design)
  • 10. Engineering Phases • Traditional = FEED then Detail Design – Concept not selected / defined – Scope for FEED not well defined – New “type” of compressor station • Efficient = Combined FEED &Detail Design – Concept is selected / defined – Scope for FEED is well defined – Basis of existing compressor station
  • 11. FEED to 30% • FID and BOD are provided • Equipment sizing, specify and place PO – LL items • Prelim P&IDs, HAZOP, Layouts, Major Piping • Detail design to 30% Model Review (incl. Constructability) Detail Design 60-90% • AFD P&IDs, update layouts, piping & E/I, incorporate vendor data • 60% Design Freeze and start IFC deliverables, P&IDs, layouts, civils • 90% Design - issue remaining IFC deliverables – piping, E/I, etc. Construction • Overlap with final Engineering detail design • Construction sequence – earthworks, civils, equipment, piping and E/I • Technical support during construction, as building, etc
  • 12. Schedule Drivers • Plan the work and work the plan • Client input and reviews (including 3rd party) • Procurement requirements – Long Lead Items (R.O.S and vendor data) – Vendor Data – key information (GA, interfaces) – Package Engineering, Expediting • Construction requirements – Construction contractor IFT packages – Appointment of Construction Contractor – IFC deliverables and sequence • Civils, Mech/Piping, E/I
  • 13. Experience • Experience leads to efficiency • Design once and build many • Standard designs • Constructability • Quality Deliverables
  • 14. Momentum’s Experience • Over 150,000 engineering and design hours for Compressor Stations and Pipelines. • Design experience across Australia – Over 10 new compressor stations across concept to DD – Upgrades to existing compressor stations – Pipeline design including, crossings, relocations and laterals • Process, Mechanical & Piping, Civil & Structural, Instrument & Electrical experience.
  • 15. Summary Engineering efficiency is gained by: • Experience • Standard design • Value engineering • Understanding project drivers • Get it right first time
  • 16. www.momeng.com.au