For most manufacturing processes, the selection and purchase of the best and most economical air emission control and energy conservation system is the first step to a successful project. A well designed and engineered system, one that matches its required specifications and that has anticipated potential process variances and unforeseen changes, is critically important. However, the project execution phase is equally crucial and includes several steps.
In the Project Execution Phase, an important moment in the project life cycle, the physical project deliverables are manufactured and/or purchased for delivery and installation at the site (with subsequent startup and turnover). This phase is usually the longest in the project life cycle and typically consumes the most energy and resources, an important factor in the selection of the original equipment purchase.
The project execution plan is the governing document that establishes the means to execute, monitor, and control the project. The plan serves as the main communication vehicle to ensure that everyone is aware and knowledgeable of project objectives and how they will be accomplished. It is the primary agreement between supplier and the purchaser and a living document that should be updated periodically to describe current and future processes and procedures, such as integrating safety into the design process.
A typical PROJECT EXECUTION PLAN will include the following (but may vary depending on the specific project and total scope):
- Project Description
- Define Work Scope
- Facility Requirements
- Project Management
- Project Team and the Organizational Structure
- Key Supporting Organizations (Including Subcontracts)
- Division of Responsibility and Delegation of Authority
- Project-Specific Training and Qualification Requirements
- Project schedule
- Project Objectives and Deliverables (Scope)
- Top Level Project Schedule and Milestones
- Reporting Requirements/Frequency
- Project Performance Metrics
- Communication Plan
- Project File Maintenance
- Project Risk Analysis
- Environment, Safety, and Health Analyses
- Project Agreements
- Lesson Learned
- Project Performance Standards/Compliance
- Customer Acceptance
- Quality Assurance
- Environmental Compliance
- Functional Operating Plans
- Engineering Plan
- Project Control Plan
- Procurement Plan
- Construction Plan
- Startup Plan
- Turnover Plan
NESTEC provides the necessary management services and technical skills to ensure that all projects will be coordinated and directed to bring about full completion on time, while meeting design and quality specifications. Towards that end, NESTEC implements the scope of services using the following critical success factors:
- Safety — We will implement a proven approach to enhance the safety of this project, including training to ensure that no lost time accidents are incurred. https://www.nestecinc.com/news/safety-first
- Project Execution — Strategic and tactical planning for the project life cycle that is developed at the start, concentrating on successful completion on time.
- Project Procedure — Proven guidelines for execution of projects within the scope of the contract, including project review meetings, updated schedules, monitoring of all purchased materials, fabrication inspections, installation inspections, start up, and provision of the necessary operating and maintenance training.
- Organization Team — Structured to function directly with both the client and NESTEC’s management, and staffed with fully qualified, experienced professionals.
- Schedule — Organized and concise planning for execution, manpower, materials, and equipment planned for the project, as well as smart utilization of a bar chart developed for project management that indicates events, start dates, duration, completion, and integration along with actual monthly status.
- Quality — Total quality management in place, with full implementation from management techniques to work inspection. The plan will cover project management, engineering, procurement, fabrication, installation, and start up services.
- Construction — Clear understanding of project scope, restraints, operational coordination with minimal interference, and innovative approaches to implementation that provide safe and successful completion of the project on time.
- Substance Abuse Policy — Promoting a high standard of safety prior to mobilization at the site.
- Checkout! Startup — A proven system for establishing a safe, fast, and efficient start up with minimal operation interference. The procedures include inspection, verification, checkout, air balancing, testing (emission tests not included), training, and turn over.
- Aftermarket and Service — Ongoing support and upgrades, potential service contracts, and online service and control diagnostics.
NESTEC offers One Single Source for a complete air emission control and energy conservation system, including project execution.
Design & Engineering of a total air emission control system, including energy conservation. Integrating all the air emission control and energy conservation requirements into a single design and engineering package will provide the best and most economical system.
Modular Design for easy field installation
NESTEC pre-assembled components in the shop to minimize:
- Installation Time
- Quality Control Issues
- Costs
Fabrication
NESTEC employs state-of-the-art manufacturing equipment, computerized steel cutting and welding, CNC machining center, continuous training, procedure updates, and extensive experience with APC Equipment fabrication.
Shipping
NESTEC coordinates shipments to minimize field handling and provide direct unload to installation. Special provisions for large modules can also be arranged.
Controls
NESTEC‘s local and burner panels receive a point-to-point wire check to ensure there are no direct shorts, any problem will be corrected at this point. The panels are powered on 120VAC/60/3 electrics and each device is exercised to verify that it is performing properly. In addition, the PLC program will be installed and checked for proper operation. At that time, the customer will be invited to sign off on the equipment, and any deviations to the contract will be corrected.
Installation
- Unpacking with description of extent of shop assembly
- Storage, if required, including instructions, if any, on how preservatives are to be maintained
- Cleaning, including the flushing of auxiliary systems: lube oil, seal oil
- Foundation preparation
- Placement on foundations and grouting
- Alignment
- External piping and instrumentation
- Allowable loading on flanges
- Requirements for filtering or trapping inlet piping
- Line cleaning (including chemical cleaning, if required) and strainer requirements
- Lube and seal oil description and charge quantities
- Special installation tools/structures, e.g. lifting bars, deadmen, guys, etc.
- Precautions
- Field hydrotest requirements, procedures, limits, etc.
Start up, Training, Service
- Review safety qualifications for all involved.
- Pre-test/post requirements
- Review burner management system action matrix to define proper shutdowns and manual reset requirements.
- Obtain all proper setpoints and purge time specifications.
- Create ACTION PLAN
- Make sure that all new gas equipment and/or major modifications are reviewed by industrial risk insurers
- Interlock/combustion related components testing
- Consult with process/control drawings to verify proper interlocks exist (Note: This checklist is a guide, customize as needed)
Priority Level:
- C = Critical (Shutdown)
- M = Mandatory (Corrective Action Plan)
- A = Awareness Items
Aftermarket Upgrades and Service Assistance
If you have an application that requires air pollution control and energy conservation, or an existing RTO or WESP that needs fine tuning to provide additional energy savings, contact NESTEC for a free process analysis and proposal.
For assistance call or e-mail NESTEC Inc. (Office: 610-323-7670) for a free evaluation of your VOC control equipment needs.
wholden@nestecinc.com (Aftermarket- Service)
Leave a Reply