Page 441 - Design of Simple and Robust Process Plants

428 Chapter 10 The Efficient Design and Continuous Improvement of High-quality Process Plants
. The ideas need to pass a first evaluation, to make a prioritized list of the ideas
based on potential benefits and to select the most promising ones for further
development.
. Reporting of brainstorming results.
. Development and selection for implementation of promising ideas by the
project team.
. Implementation.
Leading questions to create the overall mind are formulatedfrom different perspectives:
general, simple and robust plant design, world class plants, environmental and inher-
ent safer chemical process principles (CCPS, 1996; Kletz,1991). The moderator leads
the session by going step-wise through the process, and stimulates the discussion.

General points
. Do we really need this process, unit, equipment, utility? Does it add value for
the customer?
. Can we replace this functionality with an external service? Services can be
bought from an outside companies like; power, steam, water, refrigeration
cooling, cooling water, oxygen, process streams, waste water treatment.
. Can we avoid steps in the process were we increase a stream to a higher energy
level, such as temperature, pressure or concentration level, decrease it and
increase it again? (For the ªdo, undo and redoº discussion, see Chapter 5).

Simple and robust plant design
. Do we design for single robust components? (components might be a proces-
sing train, unit, equipment, line, instrument, valve, power cable, etc.).
. Can we combine this process step/equipment with another step/equipment?
. Is the design based on first-pass prime?

World Class Manufacturing
. Does the design apply for Total Quality Control? Do it right the first time.
. Is the principle of just in time production followed?
. Do we consider predictive maintenance?

Environmental
. Can we prevent or reduce this waste stream?
. Can the external risks be prevented or minimized?

Inherent safer chemical process principles
. Can we minimize the hazards (less material)?
. Can we substitute a material with a less hazardous substance?
. Can less hazardous situations be created through moderation, such as less
severe conditions, less hazardous form of materials?
. Can we simplify the design for operation, minimize direct interactions
between different sections?