What are the best ways to design a plant that is both cost-effective and efficient?

The scope will be intricately defined concerning design and minimum requirements to achieve the desired performance for EPCC (Engineering, Procurement, Construction, and Commissioning), along with operation and maintenance. The most favorable solution, agreed upon by shareholders based on technical, economical, and logistic aspects, will be outlined to determine the optimal execution schedule and minimize both CAPEX and OPEX costs. Agreed on client specifications, relevant local regulations, codes and standards to be followed which shall be used as guide to what engineering / design functions / process conditions/ deliverables are required from Contractor and constituting a contractual component of the Contractor's design scope.

When starting a new project, clearly stating goals upfront is critical to achieving an optimised design. We analyse options using process simulation and thermodynamic models, allowing for quantitative comparisons on variables such as yield, throughput, and energy utilisation. Early cross-functional engagement with process engineers helps the team align on technical requirements and limits. Duplicate effort, competing assumptions, and late-stage rework are all reduced by effective information exchange. Through reliability-centered maintenance programmes, root cause analysis, and continuous improvement initiatives, overall equipment effectiveness is maximised.

For new construction, expansions, and modifications in existing facilities, plant layouts must prioritize safety and protection against the spread of fire, ensuring ease of operation and maintenance within an economically efficient design. Factors such as topography, prevailing winds, personnel safety, and nearby population centers should guide the selection of the most suitable location. When laying out equipment, consideration must be given to the extent of hazardous areas. Efforts should be made to group equipment in areas with similar classifications and fire protection requirements. Items posing potential hazards should be grouped together and, when possible, situated separately from other plant areas.

The equipment location, considering hazardous area classification, should prioritize minimizing the use of alloy pipework and large-bore pipes while meeting the flexibility and support needs of the piping system. It is crucial to adhere to slope and no-pocket requirements. Flare headers should be sloped without pockets, directing towards flare knockout drums. Optimize the elevation of underground drain drums in high water table areas by avoiding edge placement to prevent increased depth. Consider factors such as location, sump depth, pump size, storage volume, inlet elevations, and constructability. The arrangement should maximize the use of common maintenance equipment and laydown areas with out compromising safety thus reducing plot size.

The utilization of modularized plant design and layout has the potential to reduce costs associated with site infrastructure, construction, and commissioning, while also saving time. This approach allows for work to be conducted in a controlled shop environment rather than on-site, where uncertainties and risks are more significant. Our involvement in optimizing the structure/modules aims to keep overall engineering costs within the budget without compromising delivery timelines with continuous focus on value engineering and weight control

Plant Optimization is very essential for the organisation to determine the cost effective and efficiency of the plant. Process data needs to keep balance during plant operational which leads to a maximum and effective product with minimum input. This is called optimized Process Control (OPC).