Trend for fast track project implementation grows
Bjarne Darré outlines the benefits of a 'fast track' approach to the implementation of new process plant projects.Fast track implementation of projects is the new trend within project execution. And this is no wonder since fast track is synonymous with minimisation of time to market and maximisation of return on investment and CAPEX. These are three convincing arguments in any boardroom when a decision must be made on the investment in new process plants or process lines.
However, successful implementation of a fast track project requires that customers set aside their traditional attitude to project execution.
The aim of the pre-project is to form a design basis which 'go' is given for the project. In reality, this means that detailed engineering is carried out prior to start up of the project. The most secure way is, therefore, first to select the supplier and then let this supplier carry out the pre-project. Obviously, this approach will lead to protests from the purchase department as it will be practically impossible to obtain alternative quotations or quotations for subcontracts.
However, the advantages of the fast track approach in terms of time to market, return on investment and CAPEX are far bigger as fast track execution of the project will allow the customer to bring his product to the market with several months' lead compared to traditional project execution. Moreover, the risk of large budget overruns is minimised.
When the supplier is chosen at such an early stage of the project, the selected supplier must be able to assume the entire responsibility for the supply, ie the selected supplier shall - at a minimum - understand the process and have access to all necessary process technology, and he shall be able to deliver and integrate the total supply.
The composition of the project group is an essential success criterion of a fast track project. The importance of having all stakeholders represented in the project group should not be underestimated, ie both the customer and the supplier must make available all relevant resources to the project. From the customer's side it is important that the project group not only includes the project manager and project package managers, but also any other staff group who will be involved in the operation and maintenance of the production facility later on, ie both process operators and maintenance staff.
Another important success criterion is the supplier's ability to visualise the project in the pre-project phase. With the right CAE tools the supplier can visualise the final project at a detail level giving all parties involved a total understanding of the content of the project - and thereby secure one of the absolutely most important success factors, namely mutual tuning of expectations.
As the term says a fast track project must be carried out fast. We also use the term 'dual track' for this kind of projects as two sub-projects are carried out simultaneously at two different sites; one sub-project being the total building and utility equipment supply, and the other being the total process plant supply.
In the pre-project phase the process plant supply is divided into a number of process modules to be manufactured on skids and later on transported into the finished building and connected as 'plug and play modules' so to say. Actually, there are only two factors limiting the physical size of this type of modules: transportation and the accessibility of the building.
The process modules are manufactured in a workshop off-site which does not necessarily have to be located close to the final place of installation. Manufacture of the modules in an off-site workshop is much more efficient than manufacture on site in the process building, since the welders do not have to struggle with other workmen like, for example, bricklayers, painters and electricians in order to obtain sufficient space to perform their work. Once the manufacture of each module is terminated, a complete Factory Acceptance Test is carried out ensuring that the module will be ready for test, commissioning and production upon delivery on site.
GEA Liquid Processing in Skanderborg, Denmark, has carried out several fast track projects. Lately, we have supplied the largest biotech plant in the world for production of cultures, rennet and enzymes to the food industry as a fast track project.
Enter 19A or XX at www.engineerlive.com/epe
Bjarne Darré is a Director with GEA Liquid Processing, Skanderborg, Denmark. www.gea-liquid.dk
