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Course Details
Defining a Pilot Plant Program
- What is a pilot plant?
- Defining the goals of the pilot plant
- Identifying key issues
- Selecting the appropriate strategy
- Developing a design basis
- Prototype concerns and implications
Pilot Plant Design Issues and Strategies
- Difference from process plants
- Prototype concerns
- Design approaches
- Minimizing the downside risk
- Design and construction options
- Guidelines for successful contracting
- Continuous vs. batch systems
- Attended vs. unattended operation
- Design hints
Types of Space Suitable for Pilot Plant Operations
- Separate buildings
- Containment cells
- Open bays
- Hoods and laboratory areas
- Estimating pilot plant space requirements
Pilot Plant Cost Factors
- Practical effects of budget constraints
- Estimating design and construction costs
- Similarity (standard)
- Similarity (adjusted)
- Cost ratios
- General
- Specific
- Detailed labor and materials
- Detailed labor with materials added
- Detailed materials with labor added
- Detailed labor and materials
- Issues and concerns
- Contingency
- Accuracy
Schedule Factors
- Major areas of concern
- Guidelines for effective scheduling
- Crash program risks
- Approaches to minimize problems
- Technology implications
Pilot Plant Control Systems
- Types of control systems
- Estimating system size
- Maintenance and reliability
- Contracted vs. in-house maintenance
- Control system placement options
- Guidelines for successful control rooms
- Control vs. safety systems
Pilot Plant Start-Up
- Differences from major process unit start-up
- Optimizing start up efforts
- Start-up resources
- Start-up sequences
- Equipment
- Calibration
- Turn-key vs. in-house start up
- Flushing
- Leak testing
Pilot Plant Maintenance
- Advantages of good maintenance
- Types of maintenance
- How to minimize maintenance costs
- Typical maintenance costs
- In-house vs. contracted maintenance
Operations
- Operating organization models
- Modifications vs. new construction
- Management of change
- On-line maintenance
- Coverage and shift issues
- Operational support