E. A. Hernandez, Swagelok, Solon, Ohio
When it comes to major petrochemical plant construction projects, logistical complexity can be one of the biggest hurdles builders face. Sometimes referred to as megaprojects, these plant constructions typically involve years of careful planning, engineering and development, and the coordination of dozens of global vendors and specialists (FIG. 1).
Throughout all stages of megaproject development, the owner must remember the critical nature of optimized fluid system management and planning within the complex. Small-bore tubing and tube fittings in these facilities are responsible for handling dozens of chemical processes ranging from simple utility applications to using hazardous fluids and applications involving high pressures and/or high temperatures. Ease of future maintenance is also an important consideration. For these reasons, selecting optimized fluid system fabrication components and working with the right vendors are priorities from initial planning to completion.
To achieve high levels of fluid system quality, consistency and safety, it can be advantageous to specify a single supplier for fluid system components, including valves, tubing and fittings. This will help to eliminate the potential for component intermix across the site. Consolidating suppliers can also contribute to greater fluid system reliability and maintainability sitewide, while creating cost efficiencies. Although achieving component consistency across a megaproject comes with challenges and complexities due to the project’s large scale, it can be done successfully.
To illustrate how, this article will detail the strategies that the owner of a recently completed $27-B petrochemical megaproject in the Asia-Pacific region used to achieve standardization of tubing and fittings throughout several key fluid system applications. The 22-acre complex is set to provide significant assistance in addressing the region’s growing energy needs in the coming years, with a projected capacity of 300,000 bpd of crude oil and estimated production of 7.7 MMtpy of various petrochemical products. High fluid system performance reliability levels are critical to delivering on those promises.
Anticipated challenges. Massive projects like this commonly involve many global players and vendors, which can contribute to significant complexities that can hinder successful project completions.
For example, during the construction of the Asia-Pacific megaproject, up to 70,000 people were onsite working on different facilities, applications and projects at the peak of construction activity (FIG. 2). Ensuring that installers for important applications were properly trained was a necessity. Language barriers between vendors from different countries posed communication challenges. Finally, coordinating stakeholders across borders and time zones was not always easy. Each critical application involved various engineering, procurement, construction and commissioning (EPCC) companies in different countries and required specialized expertise to design and engineer specific applications or packages.
These conditions are not unique to the Asia-Pacific project; they reflect major trends at work in the petrochemical industry. Applications and packages are becoming increasingly specialized, requiring precise knowledge and dedicated expertise.
BENEFITS OF STANDARDIZATION
Across these different applications and packages and the respective teams, standardizing critical componentry can contribute to more efficient project development and long-term reliability.
First, it is important to consider what is at stake over the long term once the complex is in operation. No matter where a facility is located, system productivity, reliability and safety are primary priorities in every application. Many critical processes involve high pressures or high temperatures and difficult—at times dangerous—fluids that must be contained within the system. Any leak can pose a safety hazard, whether minor or major, and may be detrimental to efficient production.
For these reasons, standardizing high-quality parts from a single supplier across important applications and packages is becoming a common practice (FIG. 3). In the case of the Asia-Pacific megaproject, standardization delivered some significant benefits, discussed in the following sections.
EPCCs remained on the same page. With several EPCCs onsite working on different applications, standardizing a specific make of tubing, tube fittings and other components sitewide made the project simpler for the owner-operator to manage. Project managers could validate proper installations more readily due to standard component familiarity across the complex and avoid incompatibility between different parts. Furthermore, maintenance technicians will encounter similar system configurations and componentry in the future as they maintain the plant’s fluid equipment throughout its lifetime, boosting their efficiency when troubleshooting systems and replacing parts. Additionally, by specifying one reliable supplier with a global reach, the owner-operator was assured that all the global EPCCs involved could achieve a shared understanding of the components’ performance characteristics. This coordination helped to reduce complexities during the front-end engineering and design (FEED) stage and set up the remainder of the project for success.
High component quality in every fluid system application. For critical applications, it is important to remember that not all tubes, fittings and valves are created equal. Components designed to maintain leak-tight performance and made from higher-quality alloys to better resist corrosion can help owner-operators minimize the risk of leaks, maintenance issues and potential safety hazards throughout the lifetime of their assets. When all fluid systems are made up of such components and materials, owner-operators can expect high performance for the lifetime of their operations. Standardizing high-quality components can help reduce the potential for substandard parts being used in certain areas of a major complex. The owner-operator of the Asia-Pacific megaproject heeded this advice and specified a single brand of components for all fluid system packages in the complex, helping to ensure quality and performance in each application.
Optimized labor. Standardizing components across the Asia-Pacific megaproject’s fluid systems also helped create labor efficiencies for the owner-operator. First, the practice eliminated the need for crews to be familiar with different systems and components from various manufacturers. Working with the same components from a single source helped offset a lack of installation, maintenance and operation expertise while reducing training needs. Once contractors learned how to reliably install one type of tube and fitting, they could apply those principles to every application throughout the complex. Consistent installation, operation and maintenance protocols also reduced rework needs after testing systems.
Eliminating project delays. For megaprojects, potential construction delays can lead to significant financial consequences, so the stakes are high. During the Asia-Pacific megaproject development, the potential cost if just one EPCC did not have the needed materials on hand to continue construction was approximately $1 MM/d. If those delays impacted all EPCCs, the cost could reach to $25 MM/d.
These conditions make the seamless delivery and installation of components across a project critically important, even as projects continue to be subdivided into packages involving different EPCCs. For the Asia-Pacific project, standardizing fluid components from a single reliable supplier that offered on-time delivery from regional locations helped avoid costly delays (FIG. 4).
Collaborating with your supplier. In addition to delivering high-quality fluid system components throughout a megaproject, the right supplier can provide holistic assistance through various process stages (FIG. 5).
The Asia-Pacific megaproject provides a good example. The owner-operator specified a certain brand of fitting, valve and tubing for the project's fluid system applications and packages. This allowed the supplier to become deeply familiar with the owner's established best practices and project requirements. This was beneficial throughout the early design stage for all EPCCs, particularly those new to working with the owner, allowing the overall engineering and installation process to proceed efficiently. In addition, the supplier was able to help EPCCs navigate all relevant industry requirements, permitting and certifications—all of which were highly beneficial for overall project management.
The supplier was also able to apply its skill and experience to EPCCs on applications requiring specialized knowledge. For instance, analytical sampling applications—common throughout the megaproject—often require specialization to ensure the systems, once completed, will function efficiently and safely. To those ends, the supplier helped contribute to heightened quality control throughout the installation of all analytical sampling systems.
Beyond analytical sampling systems, the owner-operator wanted to be sure that all fluid systems were installed correctly the first time to ensure long-term reliability. Here, the supplier provided certified installation training for all its components. Training included product installation and maintenance training to keep associates and contractors safe, competency and skills development to minimize errors and streamline operations, and standardized education to encourage consistent performance across all fluid systems.
Ensuring successful outcomes. The successful completion of the Asia-Pacific megaproject required the highest levels of coordination and collaboration to execute successfully, mandating teamwork on a massive scale among numerous global players. For all fluid systems involved in the project, the impact of selecting the right supplier was significant, helping the owner-operator manage resources and components throughout all construction areas via in-depth knowledge of the industry, customer specifications and government regulatory mandates.
The demands are similar for any of today’s new major petrochemical projects. Owner-operators should look for agility, collaboration and accountability when choosing a supplier of critical fluid system components. A global presence—with the logistical capabilities to supply massive numbers of the required components on schedule—is also an important quality to seek. Finally, a supplier that can provide consultation and training to solve problems onsite as they may arise can help contribute to improved project efficiency and on-schedule completion. A supplier that can deliver on each of these needs for owner-operators can contribute to a successful project. HP
EDWARD A. HERNANDEZ is the Global Sales Manager of Global Construction for Swagelok Company. Hernandez can be reached at edward.hernandez@swagelok.com.