Feasibility Studies and Conceptual/Preliminary Process Design (pre-FEED)
From Conceptual and Preliminary Process Designs
When clients are contemplating a new plant or major process expansion, they typically have more questions than answers. Will the idea even work? PROCESS is able to assist by providing experienced and knowledgeable chemical engineers that can identify, and systematically narrow down, the possible technical options for a given process goal. By necessity this occurs at the major unit operations level. Once the viable technical options are identified, an economic evaluation is performed. Based on technical merits, system reliability, and economics (capital and operating), and other factors, a preferred choice is usually clear as to which direction the future process design should take. At this point a conceptual design can be done that includes preliminary process flow diagrams, mass & energy balances, and a list of major equipment. A very rough order of magnitude cost estimate can be provided as well.
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Some industry segments, mainly refining, refer to ...
Some industry segments, mainly refining, refer to this type of work as FEL-0 and FEL-1, where FEL refers to Front End Loading. It is widely recognized that this key front end work will have a major impact on the overall project and ultimate operation. If you don't get this right then your project is in trouble no matter how good the subsequent detail engineering, construction, and project management work are executed.
FEL 0 - Identification Phase
Project opportunities arise through outside proposals, management directives, or individual initiatives. These opportunities can target revenue growth, expense reductions, strategic growth, or improved reliability, efficiency or maintenance. We first identify the opportunities by evaluating their value and identifying key risks and uncertainties. It is important to evaluate these opportunities on a consistent basis for accurate relative comparison purposes. The basis for the first decision gate (sometimes referred to as MR-1) is typically a Class V cost estimate with premises for economic modeling typically ranging from –20% to +50%.
FEL 1 - Appraisal and Selection Phases
Appraisal
Each project that successfully gets MR-1 approval progresses to the Appraise phase, where a thorough set of development alternatives is prepared and further assessment of process value, risk, and uncertainty is conducted. From a facilities perspective, some engineering may be required to further refine cost and schedule deliverables, although these should be closely managed to expend funds only where value is added. The best development concepts are moved forward to the Select phase.
Selection
Further study of multiple development options occurs in the Selection phase with the objective of identifying a single process concept for progression to the Optimization phase and subsequent final detail process design package development. Preparation of work deliverables require that a single viable concept be selected and further developed during this phase. Well-defined selection criteria should be established at the beginning of this phase to ensure the most efficient use of resources (time, money, and manpower). Once a concept has been selected, the team will complete the level of detail necessary to develop a cost estimate and preliminary project schedule with a typical accuracy of –20% to +40%.
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