Pilot Plant Design, Construction and Operation

20 hours

This course focuses on the critical components for a successful pilot plant program. It is intended for pilot plant project managers, supervisors, designers and operators, as they design, build and operate pilot plants. It is suitable for all levels from inexperienced to very experienced.

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