The document discusses expanding an existing water treatment plant by installing 16 new reverse osmosis (RO) units to increase production from 400 to 1000 gallons per minute. A value engineering study was conducted to evaluate proposals, including using seawater membranes, eliminating demineralizers and a deaerator. The recommended proposal would save an estimated 44% of the original cost while still meeting water quality requirements.

1. King Fahad University of Petroleum & Minerals Term Project Expansion of Water Treatment Plant Sagar M. Al-Anazi CEM-512 VALUE ENGINEERING

3. Reverse Osmosis Process CEM-512 VALUE ENGINEERING Feed Pretreatment Process RO Process Demineralization Process Condensate Water Tanks

8. Information Phase Consultation Record CEM-512 VALUE ENGINEERING Saudi Aramco CSD RO Vendor SIDMAS RO Vendor AES Major Points Contact

9. Cost Data Information Phase Tot. Cost = $ 9,550,000 CEM-512 VALUE ENGINEERING 150,000 75,000 Chemical Injection Facilities 4,000,000 1,000,000 4 Deminilizers 500,000 500,000 One Deaerator 4,000,000 250,000 16 RO Units 900,000 150,000 6 Pretreatments Filters Cost ($) Unit Price ($) Particular

11. Functional Phase Functional Worksheet CEM-512 VALUE ENGINEERING Expansion of the RO Plant Produce industrial Water To Support Plant Operations How Function Why

14. Evaluation Phase Ideas Comparison CEM-512 VALUE ENGINEERING 2 1 3 Rank Increase the load on other plants Reduction in the cost Eliminate Deareator Increase the load on the membranes Reduction in the cost Reduction in chemical consumption Eliminate Deminilizeras Required close monitoring High water quality TDS < 5 ppm Use Sea water spiral wound membranes Disadvantage Advantage Idea

15. Evaluation Phase A. Initial Cost B. Operation & Maintenance C. Reliability D. Environmental Impact How Important 3. Major Preference 2. Medium Preference 1. Minor Preference Raw Score Assigned Weight Criteria Determining Weight for Evaluation 7 4 3 1 6 2 5 10 CEM-512 VALUE ENGINEERING D C-2 C B-3 /C B B A-3 A-2 A-2 A D C B

16. Evaluation Phase Initial Cost Oper & Maint. Envir. Impact Reliability Use Sea Water SW Membranes Idea 2 Eliminate Deminilizers Eliminate Deareator Evaluation Matrix CEM-512 VALUE ENGINEERING 42 56 47 SUP TOT P P P P 1 F F F F 2 G G G G 3 VG VG VG VG 4 Rank E E E E 5 SUP TOT P P P P 2 F F F F 2 G G G G 3 VG VG VG VG 4 Rank E E E E 5 Idea 3 SUP TOT P P P P 1 F F F F 2 G G G G 3 VG VG VG VG 4 Rank E E E E 5 Idea 1 1 3 4 7 Total Assigned Value WT Ideas

17. Development Phase Additional Information Additional information was collected to develop the alternatives. 1. Equipments specifications. 2. VE team consulted RO manufactures like Toray (website). CEM-512 VALUE ENGINEERING

18. CEM-512 VALUE ENGINEERING Development Phase The Initial Cost of Deminilizer = $ 1,000,000 Annual maintenance cost = $ 13,000 Salvage value = $ 30,000 Interest rate = 5% Service life = 20 years Then, P = 1000,000+ 13000(12.4622) – 30,000 (0.3769) = $ 1,150,702.0 The original Life cycle of Deminilizers 1,000,000 30,000 13,000 20 0

19. CEM-512 VALUE ENGINEERING Development Phase Original: Install 4 Deminilizers. Proposed: Eliminate the deminilizers $ 4,000,000 Total Cost Item $ 0 Saving in Initial Cost = 4,000,000 Original Life cycle cost = 4,602,808 Proposed Life cycle cost = $ 0 Saving in Life cycle cost = 4,602,808

20. CEM-512 VALUE ENGINEERING Development Phase The Initial Cost of Deaerator = $ 500,000 Annual maintenance cost = $ 6,000 Salvage value = $ 12,000 Interest rate = 5% Service life = 20 years Then, P = 500,000+ 6000(12.4622) – 12,000 (0.3769) = $ 570,251.0 The original Life cycle of Deaerator 500,000 12,000 6,000 20 0

21. CEM-512 VALUE ENGINEERING Development Phase Original: Install a Deaerator Proposed: Eliminate the deaerator $ 500,000 Total Cost Item $ 0 Saving in Initial Cost = 500,000 Original Life cycle cost = $ 570,251.0 Proposed Life cycle cost = $ 0 Saving in Life cycle cost = $ 570,251.0

22. CEM-512 VALUE ENGINEERING Development Phase The Initial Cost of RO Unit = $ 250,000 Annual maintenance cost = $ 8,000 Salvage value = $ 9,000 Interest rate = 5% Service life = 20 years Then, P = 250,000+ 8,000(12.4622) – 9,000 (0.3769) = $ 346,306 The original Life cycle of RO Unit 250,000 9,000 8,000 20 0

23. CEM-512 VALUE ENGINEERING Development Phase The Initial Cost of RO Unit = $ 270,000 Annual maintenance cost = $ 8,000 Salvage value = $ 9,000 Interest rate = 5% Service life = 20 years Then, P = 270,000+ 8,000 (12.4622) – 9,000 (0.3769) = $ 366,306 The proposed Life cycle of RO Unit 270,000 9,000 8,000 20 0

24. CEM-512 VALUE ENGINEERING Development Phase Original: Install 16 RO Units Proposed: Install 16 RO Units and Use Sea Water Membranes $ 4,000,000 Total Cost Item $ 4,800,000 Increase in Initial Cost = $ 800,000 Original Life cycle cost = $ 346,306/Unit = $ 5,540,896 Proposed Life cycle cost = $ 366,306/unit = $ 5,860,896 Increase in Life cycle cost = $ 320,000

25. Development Phase Saving in Initial Cost = $ 4,180,000 = 44% Reduction Proposed Cost = $ 5,370,000 Original Cost = $ 9,550,000 CEM-512 VALUE ENGINEERING Total Saving 150,000 75,000 Chemical Injection Facilities 4,320,000 270,000 16 RO Units 900,000 150,000 6 Pretreatments Filters Cost ($) Unit Price Particular