Superior design requires superior Conceptual Engineering. The Conceptual Engineering phase of process engineering projects determines most of the ultimate operability, maintainability, reliability, capacity, and efficiency of the final process system. Integrated Technologies, Inc.’s (ITI) process engineering approach assures that environmental, health, and safety performance and efficient process flow are also designed in during the conceptual engineering phase. Superior layout design is essential to efficient process flow. ITI has been designing lean and green processes for over 28 years. Conceptual Process Engineering is both a sequential and an iterative process. ITI’s design methodology assures that the basis of design is well documented and that all stakeholders have signed off on process requirements and project planning. Projects often include cost estimating and logistical (detailed design, procurement, construction, start-up, commissioning, and training) planning. ITI’s sequential and iterative design process facilitates visualization and evaluation of alternative process designs and scenarios. Our Conceptual Process Engineering and Design projects normally include six integrated steps:
Step One: Define the project objectives in terms of problems or needs. The project definition should include review and documentation of budget and schedule constraints.
Step Two: Document the current process (as required) and review process specifications, policies, and regulations. Document process chemistry and materials and collect required MSDS and TDS documents. Document process hazards and EH&S goals. Develop process flow diagrams (work flow).
Step Three: Document the basis of design. Document the production basis, including load size (work envelopes, surface area, and weight) and production rates (loads/hr., hrs./day, days/week, weeks/year). Document process capability and reliability requirements. Document part substrates, part complexity, and special tooling requirements.
Step Four: Size major equipment. Develop preliminary equipment schedules for major equipment. Develop process flow diagrams (energy and material flow).
Step Five: Develop process adjacency maps, process layout alternatives, and space planning. Evaluate process layout alternatives for work flow, part handling, operability, maintainability, tank inspection & repair, chemical handling, hazard management, secondary containment, waste stream segregation, characterization and collection, ventilation, segregation layout & efficiency, mechanical and electrical services, rectifier bussing and cooling, material handling (cranes, hoists, shuttles, carts, etc.), tooling storage and retrieval, and racking and unracking. Evaluate renovation and/or construction logistics.
Step Six: Develop ROM capital and operating cost estimates. Develop preliminary Design-Bid-Build or Design-Build project schedule.
