500 Ton Air-cooled Water Chiller Project
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WEATHERFORD INTERNATIONAL, INC. PROJECT DELIVERY FRAMEWORK
Weatherford Engineered Chemistry
500 Ton Air-Cooled Water Chiller VERSION: 1.0
REVISION DATE: 12/14/2007
Approval of the Project indicates an understanding of the purpose and content described in this document. By signing this document, each individual agrees work should be initiated on this project and necessary resources should be committed as described herein. Approver Name
Title
Greg Schmidt
Project Manager
Scott Lysko
Global Manufacturing Manager
Gil Rodriguez
Manufacturing Manager
Terri Harrison
QHSE Director
Signature
Date
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Contents Section 1. Project Overview .................................................................................1 1.1 1.2 1.3 1.4 1.5 1.6 1.7
Problem Statement .............................................................................1 Project Description ..............................................................................1 Project Goals and Objectives..............................................................1 Project Scope......................................................................................1 Critical Success Factors .....................................................................3 Assumptions........................................................................................3 Constraints ..........................................................................................3
Section 2. Project Authority and Milestones ........................................................4 2.1 2.2 2.3
Funding Authority ................................................................................4 Project Oversight Authority .................................................................4 Major Project Milestones.....................................................................5
Section 3. Project Organization ...........................................................................6 3.1 3.2
Project Structure .................................................................................6 Roles and Responsibilities..................................................................7
Section 4. Points of Contact.................................................................................8 Section 5. Glossary ..............................................................................................9 Section 6. Revision History ................................................................................10 Section 7. Appendices .......................................................................................11
Page i
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 1. Project Overview 1.1
Problem Statement Currently the Elmendorf facility chilled water system is supplied by a Carrier 200 ton air-cooled chiller. Due to increase in production forecasted over the next five years, the need for a 500 ton air-cooled chiller has been determined. The existing Chiller has incurred more downtime in 2006 as a result of being overloaded. The Chiller was originally purchased 4 years ago, and was intended to only handle the five (5) reactors in the east (Area 200) manufacturing area. The supply of chilled water services all areas of the plant, and has put a severe strain on the current system. The installation of a new 500 ton chiller will allow for the 200 ton chiller to offer full support to the reactors in the south (Area 400) plant, and will also serve as a back up system for the new 500 ton chiller. The Carrier 500 ton chiller will service the Areas 200 and 300 of the facility. This project also includes the relocation of the Thermal Oxidizer unit. This will allow the 200 ton chiller to be positioned to service Area 400.
1.2
Project Description The approach to this problem is to acquire a Carrier 500 ton chiller to replace the original 200 ton chiller that serviced the process facility. The 200 ton chiller will then be relocated to the south side of the plant to service the four (4) reactors in Area 400. Both chillers will be elevated on steel structures to reduce space consumption. Both chillers will have individual storage vessels and pumps located under the steel structures. In addition, new insulated chilled water piping will be installed on newly constructed pipe racks. The pipe racks will be constructed in three phases. The pipe racks will also house the steam generation piping, process piping and the nitrogen piping for the process plant. The new pipe racks will be equipped with handrails, an enclosed ladder for access, lifeline support, and grating.
1.3
Project Goals and Objectives The business goals and objectives of this project is to accommodate the demand of the entire facility with adequate chilled water and steam supply using automation between the two chillers, two boilers and twelve (12) individual reactors. The main focus of the project is having this completed in ten (10) months from the starting date of August 13, 2007.
1.4
Project Scope Identified changes in equipment configuration, control sequences and operational parameters to reduce energy consumption and upgrade the reliability and performance of the critical cooling system at Weatherford’s Engineered Chemistry Elmendorf, Texas plant. The Project will improve system reliability, reduce maintenance cost, expand system automation and provide a more stable chilled water service to the processing functions. The existing chilled water system runs on a primary pump system with no control valves. The request is made to modify the system to operate on a controlled primary and a secondary pump system. This will allow for greater energy savings and control.
Page 1
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Project Includes Furnish labor and equipment to relocate one (1) 200 ton chiller and associated pumps. This proposal is based on relocating the 200 ton chiller over a weekend and bringing the chiller back on line by Monday morning. Brandt Engineering will furnish one temporary 200 ton chiller while relocating the existing 200 ton chiller to prevent any unnecessary downtime. Furnish labor and equipment to relocate existing chill water storage tank. Furnish labor and equipment to set one (1) new Carrier 500 ton air cooled chiller. This proposal includes the purchase and coordination for delivery of the Carrier chiller. Furnish labor and materials to install two (2) new chill water pumps. Furnish labor and materials to install new carbon steel weld pipe, fittings, valves and hangers for the chill water piping. Chill water piping will be sized accordingly to handle the following reactors and receivers: R-201, R-202, R-203, R-205, R-206, R-209, R-210, R-211, R-212, V-204, V-310, V-211, R-421, V-421, V-420, and R-420. This proposal is based on routing new pipe in a newly constructed pipe bridge with cat walk that will be provided by others. Furnish labor and materials to install automatic flow control valves for the coils associated with the above mentioned reactors and receivers. Furnish labor and materials to install new steam and condensate carbon steel pipe, fittings, traps, valves and support. This proposal is based on routing new pipe in a newly constructed pipe bridge with cat walk that will be provided by others. We have included additional support for the steam pipe that will be routed to the south side of the plant where no pipe bridge will be constructed. Furnish and install domestic water piping, fittings and valves for the new 500 ton chiller and the relocated 200 ton chiller. Furnish labor and equipment to demo and remove all existing pipe associated with the 200 ton chill water system once new pipe has been installed. We will coordinate with Weatherford for shut down and the switch over for each reactor and receiver from the old chill water/steam system to the new chill water/steam system. Furnish labor to provide and install any safety items required to perform the installation of the new chill water and steam system. Safety items provided but not limited to: fire watch, fall protection, fire blankets, fire retardant clothing, fire extinguishers, etc. Furnish and install fiberglass insulation with aluminum jacket for chill water and steam piping. Furnish labor and materials to modify storage tank piping by perforating the pipe that will be installed at the top of the storage tank.
Controls: Furnish labor and materials to install explosion proof control valves for each reactor and receiver listed above. Furnish controls for the existing boiler, 200 ton chiller and 500 ton chiller for the enable/disable of steam and chill water at each reactor. This proposal is based on a control room being utilized at the south west corner of the Reactor plant. Furnish and install conduit, control wire, relays, etc. for a complete control system. Furnish one (1) new computer for the control system. Furnish programming and graphics. Furnish and install alarm system for reactors for temperature monitoring.
Page 2
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Project Excludes Patching of concrete, masonry, brick, etc Consequential damages to be limited to insurance maximum Payment or performance bond Temporary cooling/temporary chiller Flashing or patching of any roof penetrations Painting or priming of any kind
1.5
Critical Success Factors The factors or characteristics that are deemed critical to the success of a project, such that, in their absence the project will fail, is •
The cooperation of management to move forward with the project,
•
To listen, to support and to trust in the capabilities’ of the engineer and project manager.
•
Integrated teamwork between Weatherford Engineered Chemistry and Brandt Engineering.
•
Having a well-established controls system in place.
The project will ear-mark the beginning of proper controls/automation within the process facility. The next phase of automation would be Area 200. This will service Reactors 3, 6, 5, and 11.
1.6
Assumptions No assumptions are made.
1.7
Constraints No project constraints are being imposed at this time.
Page 3
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 2. Project Authority and Milestones 2.1
Funding Authority The funding amount and source of authorization and method of finance is through a capital budget needed for the approval of this project. The estimate cost of this project is $1.9 million.
2.2
Project Oversight Authority All issues and risks will be summarized in the weekly project team agenda for review and mitigation activities. Project oversight will take place weekly in the project team meeting which will include the project sponsors, key team members, and the project manager. Additional meetings, discussions, emails, and general communications will supplement the weekly project team meetings to address follow-up activities, detailed issue resolution, general strategy discussions, and so forth. The project meetings will address the following items: ¾
Reduce project risk
¾
Reduce costly project rework
¾
Establish statewide project management process standards
¾
Effectively manage expectations for the project at all levels
¾
Improve accountability of project teams and vendors
¾
Improve reporting and communication between impacted stakeholders
¾
Provide early warning to management to address critical issues
¾
Improve project decision-making at all levels
¾
Enable collection and consolidation of metrics for future project planning.
¾
Implement projects within the expected scope, schedule, budget, and quality constraints
¾
Provide guidance and tools for documentation, review, assessment, and approval of project outcomes
¾
Provide criteria to assess whether projects should continue or if they require redefinition
Page 4
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
2.3
[1.0] | [12.14.2007]
Major Project Milestones
Milestone/Deliverable
Target Date
Appropriate project monies. Submit AFE
02/15 – 03/13/2008
Install Phase I Pipe Rack (Separate AFE)
01/07 - 01/24/2008
Project Authorized for Chiller Project
03/13/2008
Finish Phase II Pipe Rack
04/08/2008
Finish construction of 200 ton chiller platform
04/09/2008
New TO Unit Installation Completed
04/18/2008
Start construction of steel platform for 500 ton Chiller
04/15 - 04/23/2008
Finish Phase III Pipe Rack
04/25/2008
Project Completed
05/23/2008
Page 5
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 3. Project Organization 3.1
Project Structure
Global Manufacturing Manager
Mfg. Manager
Project Manager
Chemical Engineer
QHSE Director
Project Drafter
Page 6
Process Manager
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
3.2
[1.0] | [12.14.2007]
Roles and Responsibilities
Role
Responsibility
Global Manufacturing Manager Manufacturing Manager Project Manager QHSE Director Process Manager Chemical Engineer Project Drafter
To help develop and plot any PI&Ds and/or demolition/construction drawings
Page 7
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 4. Points of Contact
Role
Name/Title/Organization
Phone
Engineer of Project
Paul Gerber/Chemical Engineer/WEC
210.626.0852 [email protected]
Project Manager
Greg Schmidt/Project Manager
210.626.0814 [email protected]
Contractor
Chris Humphries/Manager/Brandt
210.599.6120 [email protected]
Contractor
Roger Martinez/Beicker Engineering
210.824.2908 [email protected]
Page 8
Email
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 5. Glossary
Page 9
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 6. Revision History Version
Date
Name
Description
Page 10
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 7. Appendices
Page 11
Weatherford Engineered Chemistry
500 Ton Air-Cooled Water Chiller VERSION: 1.0
REVISION DATE: 12/14/2007
Approval of the Project indicates an understanding of the purpose and content described in this document. By signing this document, each individual agrees work should be initiated on this project and necessary resources should be committed as described herein. Approver Name
Title
Greg Schmidt
Project Manager
Scott Lysko
Global Manufacturing Manager
Gil Rodriguez
Manufacturing Manager
Terri Harrison
QHSE Director
Signature
Date
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Contents Section 1. Project Overview .................................................................................1 1.1 1.2 1.3 1.4 1.5 1.6 1.7
Problem Statement .............................................................................1 Project Description ..............................................................................1 Project Goals and Objectives..............................................................1 Project Scope......................................................................................1 Critical Success Factors .....................................................................3 Assumptions........................................................................................3 Constraints ..........................................................................................3
Section 2. Project Authority and Milestones ........................................................4 2.1 2.2 2.3
Funding Authority ................................................................................4 Project Oversight Authority .................................................................4 Major Project Milestones.....................................................................5
Section 3. Project Organization ...........................................................................6 3.1 3.2
Project Structure .................................................................................6 Roles and Responsibilities..................................................................7
Section 4. Points of Contact.................................................................................8 Section 5. Glossary ..............................................................................................9 Section 6. Revision History ................................................................................10 Section 7. Appendices .......................................................................................11
Page i
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 1. Project Overview 1.1
Problem Statement Currently the Elmendorf facility chilled water system is supplied by a Carrier 200 ton air-cooled chiller. Due to increase in production forecasted over the next five years, the need for a 500 ton air-cooled chiller has been determined. The existing Chiller has incurred more downtime in 2006 as a result of being overloaded. The Chiller was originally purchased 4 years ago, and was intended to only handle the five (5) reactors in the east (Area 200) manufacturing area. The supply of chilled water services all areas of the plant, and has put a severe strain on the current system. The installation of a new 500 ton chiller will allow for the 200 ton chiller to offer full support to the reactors in the south (Area 400) plant, and will also serve as a back up system for the new 500 ton chiller. The Carrier 500 ton chiller will service the Areas 200 and 300 of the facility. This project also includes the relocation of the Thermal Oxidizer unit. This will allow the 200 ton chiller to be positioned to service Area 400.
1.2
Project Description The approach to this problem is to acquire a Carrier 500 ton chiller to replace the original 200 ton chiller that serviced the process facility. The 200 ton chiller will then be relocated to the south side of the plant to service the four (4) reactors in Area 400. Both chillers will be elevated on steel structures to reduce space consumption. Both chillers will have individual storage vessels and pumps located under the steel structures. In addition, new insulated chilled water piping will be installed on newly constructed pipe racks. The pipe racks will be constructed in three phases. The pipe racks will also house the steam generation piping, process piping and the nitrogen piping for the process plant. The new pipe racks will be equipped with handrails, an enclosed ladder for access, lifeline support, and grating.
1.3
Project Goals and Objectives The business goals and objectives of this project is to accommodate the demand of the entire facility with adequate chilled water and steam supply using automation between the two chillers, two boilers and twelve (12) individual reactors. The main focus of the project is having this completed in ten (10) months from the starting date of August 13, 2007.
1.4
Project Scope Identified changes in equipment configuration, control sequences and operational parameters to reduce energy consumption and upgrade the reliability and performance of the critical cooling system at Weatherford’s Engineered Chemistry Elmendorf, Texas plant. The Project will improve system reliability, reduce maintenance cost, expand system automation and provide a more stable chilled water service to the processing functions. The existing chilled water system runs on a primary pump system with no control valves. The request is made to modify the system to operate on a controlled primary and a secondary pump system. This will allow for greater energy savings and control.
Page 1
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Project Includes Furnish labor and equipment to relocate one (1) 200 ton chiller and associated pumps. This proposal is based on relocating the 200 ton chiller over a weekend and bringing the chiller back on line by Monday morning. Brandt Engineering will furnish one temporary 200 ton chiller while relocating the existing 200 ton chiller to prevent any unnecessary downtime. Furnish labor and equipment to relocate existing chill water storage tank. Furnish labor and equipment to set one (1) new Carrier 500 ton air cooled chiller. This proposal includes the purchase and coordination for delivery of the Carrier chiller. Furnish labor and materials to install two (2) new chill water pumps. Furnish labor and materials to install new carbon steel weld pipe, fittings, valves and hangers for the chill water piping. Chill water piping will be sized accordingly to handle the following reactors and receivers: R-201, R-202, R-203, R-205, R-206, R-209, R-210, R-211, R-212, V-204, V-310, V-211, R-421, V-421, V-420, and R-420. This proposal is based on routing new pipe in a newly constructed pipe bridge with cat walk that will be provided by others. Furnish labor and materials to install automatic flow control valves for the coils associated with the above mentioned reactors and receivers. Furnish labor and materials to install new steam and condensate carbon steel pipe, fittings, traps, valves and support. This proposal is based on routing new pipe in a newly constructed pipe bridge with cat walk that will be provided by others. We have included additional support for the steam pipe that will be routed to the south side of the plant where no pipe bridge will be constructed. Furnish and install domestic water piping, fittings and valves for the new 500 ton chiller and the relocated 200 ton chiller. Furnish labor and equipment to demo and remove all existing pipe associated with the 200 ton chill water system once new pipe has been installed. We will coordinate with Weatherford for shut down and the switch over for each reactor and receiver from the old chill water/steam system to the new chill water/steam system. Furnish labor to provide and install any safety items required to perform the installation of the new chill water and steam system. Safety items provided but not limited to: fire watch, fall protection, fire blankets, fire retardant clothing, fire extinguishers, etc. Furnish and install fiberglass insulation with aluminum jacket for chill water and steam piping. Furnish labor and materials to modify storage tank piping by perforating the pipe that will be installed at the top of the storage tank.
Controls: Furnish labor and materials to install explosion proof control valves for each reactor and receiver listed above. Furnish controls for the existing boiler, 200 ton chiller and 500 ton chiller for the enable/disable of steam and chill water at each reactor. This proposal is based on a control room being utilized at the south west corner of the Reactor plant. Furnish and install conduit, control wire, relays, etc. for a complete control system. Furnish one (1) new computer for the control system. Furnish programming and graphics. Furnish and install alarm system for reactors for temperature monitoring.
Page 2
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Project Excludes Patching of concrete, masonry, brick, etc Consequential damages to be limited to insurance maximum Payment or performance bond Temporary cooling/temporary chiller Flashing or patching of any roof penetrations Painting or priming of any kind
1.5
Critical Success Factors The factors or characteristics that are deemed critical to the success of a project, such that, in their absence the project will fail, is •
The cooperation of management to move forward with the project,
•
To listen, to support and to trust in the capabilities’ of the engineer and project manager.
•
Integrated teamwork between Weatherford Engineered Chemistry and Brandt Engineering.
•
Having a well-established controls system in place.
The project will ear-mark the beginning of proper controls/automation within the process facility. The next phase of automation would be Area 200. This will service Reactors 3, 6, 5, and 11.
1.6
Assumptions No assumptions are made.
1.7
Constraints No project constraints are being imposed at this time.
Page 3
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 2. Project Authority and Milestones 2.1
Funding Authority The funding amount and source of authorization and method of finance is through a capital budget needed for the approval of this project. The estimate cost of this project is $1.9 million.
2.2
Project Oversight Authority All issues and risks will be summarized in the weekly project team agenda for review and mitigation activities. Project oversight will take place weekly in the project team meeting which will include the project sponsors, key team members, and the project manager. Additional meetings, discussions, emails, and general communications will supplement the weekly project team meetings to address follow-up activities, detailed issue resolution, general strategy discussions, and so forth. The project meetings will address the following items: ¾
Reduce project risk
¾
Reduce costly project rework
¾
Establish statewide project management process standards
¾
Effectively manage expectations for the project at all levels
¾
Improve accountability of project teams and vendors
¾
Improve reporting and communication between impacted stakeholders
¾
Provide early warning to management to address critical issues
¾
Improve project decision-making at all levels
¾
Enable collection and consolidation of metrics for future project planning.
¾
Implement projects within the expected scope, schedule, budget, and quality constraints
¾
Provide guidance and tools for documentation, review, assessment, and approval of project outcomes
¾
Provide criteria to assess whether projects should continue or if they require redefinition
Page 4
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
2.3
[1.0] | [12.14.2007]
Major Project Milestones
Milestone/Deliverable
Target Date
Appropriate project monies. Submit AFE
02/15 – 03/13/2008
Install Phase I Pipe Rack (Separate AFE)
01/07 - 01/24/2008
Project Authorized for Chiller Project
03/13/2008
Finish Phase II Pipe Rack
04/08/2008
Finish construction of 200 ton chiller platform
04/09/2008
New TO Unit Installation Completed
04/18/2008
Start construction of steel platform for 500 ton Chiller
04/15 - 04/23/2008
Finish Phase III Pipe Rack
04/25/2008
Project Completed
05/23/2008
Page 5
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 3. Project Organization 3.1
Project Structure
Global Manufacturing Manager
Mfg. Manager
Project Manager
Chemical Engineer
QHSE Director
Project Drafter
Page 6
Process Manager
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
3.2
[1.0] | [12.14.2007]
Roles and Responsibilities
Role
Responsibility
Global Manufacturing Manager Manufacturing Manager Project Manager QHSE Director Process Manager Chemical Engineer Project Drafter
To help develop and plot any PI&Ds and/or demolition/construction drawings
Page 7
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 4. Points of Contact
Role
Name/Title/Organization
Phone
Engineer of Project
Paul Gerber/Chemical Engineer/WEC
210.626.0852 [email protected]
Project Manager
Greg Schmidt/Project Manager
210.626.0814 [email protected]
Contractor
Chris Humphries/Manager/Brandt
210.599.6120 [email protected]
Contractor
Roger Martinez/Beicker Engineering
210.824.2908 [email protected]
Page 8
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 5. Glossary
Page 9
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 6. Revision History Version
Date
Name
Description
Page 10
Weatherford Engineered Chemistry
PROJECT DESIGN
500 Ton Air-Cooled Water Chiller
[1.0] | [12.14.2007]
Section 7. Appendices
Page 11
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