EPC turnkey project

Engineering

Synopsis Chemitech is an EPC Supplier with a highly qualified engineering department holding good knowledge of our customers’ needs as well as specialized knowledge and methods for composite engineering. The engineering group consists of highly skilled engineers with vast knowledge of design, fabrication and analysis of various chemicals processes.

Engineering & Design works are performed through coordination and teamwork among the specialized discipline engineers and project engineers who manage overall EPC activities. Based on the basic design package (FEED) and starting from process design, facilities design such as various Equipment/ Electrical/ Control & Systems and space-integration designs such as Piping/ Civil/ Building are performed in parallel manner. Close communication among the engineers is very important. At the early stage of engineering & design phase, Synopsis Chemitech especially cares for environmental and safety requirements and plant operability / maintainability considerations to be firmly incorporated. It is also required to consider and incorporate natural conditions of the construction site, such as geotechnical / geophysical/ geological conditions, climate conditions, etc. design methodology, know-how and experiences of are integrated in “Synopsis Knowledge Data Base”, which serves for the engineers to effectively share information/ skills and also succeed to technological legacy. as part of reliability program, Synopsis Chemitech performs intensive design review to make sure most the effective/ reliable engineering performance is achieved.


Procurement 

The procurement department are very important for EPC turnkey project because it is at the middle position of EPC project. EPC stands for Engineering, Procurement and Construction. These are the three main components of plant engineering. The procurement department connects engineering and construction by cooperating closely on projects.

The main task of the procurement department includes the procurement of materials within the working budget of projects; production progress control after order; and quality control by inspections and transportations to sites according to a project schedule.

The persons working in this department have the requisite knowledge / skills such as sensitivities for market trends, correct understanding of international regulations, calm judgment for prices, strength to negotiate with suppliers, and strong will power for tough quality requirements.


Construction

Plant construction starts with site survey, utility supply, land formation, camp construction to prepare for full-scale operation. Then construction processes follow ranging from foundation work, above ground structure framing, piping and equipment installation, electric and instrument system setup, to painting and insulation, etc. Situated at the project last execution stage, unexpected difficulties arise at this stage from various factors by design, procurement, and others. but expertise in planning and management together with team collaboration and efforts would make it possible to overcome and sublime the difficulties to accomplishment. patience and persistence are essential here, but the supreme satisfaction of achievement can also be shared by all the people involved at this stage.

  1. Construction Site Management and Supervision
  • General construction site management and organization
  • Construction site planning, coordination and administration
  • Supervision of erection and installation work
  • Coordination of commissioning and plant tests
  • Acceptance and performance tests, plant take-overs
  • Quality and safety management
  1. Interdisciplinary Facility Installation
  • Supervising interdisciplinary installations and coordinating individual disciplines that are normally separate from one another; installation work within Synopsis Chemitech;
  • Installation of steelworks, pipelines and piping
  • Installation of mechanical machinery, plant sections and components (waste heat boilers, boiler systems, cooling stacks, skirts and cleaning systems, chemical reactors; static and rotating machinery, appliances, vessels, etc.)
  • Installation of EMSR equipment and systems
  • Quality and safety management
  1. Plant Construction, Erection and Commissioning
  • The EPC turnkey project by Synopsis Chemitech, we take care of all erection, construction and commissioning work as well as construction site management for greenfield/brownfield projects.
  • Complete construction site management and administration
  • Supervision of the erection of steelworks and pipelines
  • Realization of mechanical plants, plant sections and systems
  • Coordination of sub-systems with third-party providers
  • Pre-testing and installation of all machinery
  • Acceptance on site of facilities/systems/components/installations
  • Planning and coordination for commissioning
  • Function tests for machinery and complete plants, system tests, fine-tuning
  • Performance tests
  • Plant take-overs
  • Spare part management on the construction site
  • Construction site documentation
  • Operating and maintenance guides
  • Quality and safety management
  • Transport and logistics

Commissioning

Chemical plant commissioning is a vital step near the end of a plant’s construction, its purpose is to hand over a safe, efficient and operation-ready facility to the owner. It is the planned coordination and execution of the final stages of construction and the beginning of production.

A detailed, systematic commissioning plan created by Synopsis Chemitech can reduce the overall time between completion of construction and the start of facility operations, and verify that the equipment and systems installed meet the design intent.

Chemical plant commissioning is performed before commercial operation after completion of construction of the plant. Chemical plant commissioning activities are intended to ensure that the plant will operate in accordance with design and project specifications. Synopsis Chemitech believes that successful commissioning is the most important phase of the project because it is directly linked to customer satisfaction and benefit. Commissioning is a highly specialized area which requires a complex mix of capabilities developed through wide experience and engineering knowledge. The required capabilities include knowledge in newly developed process, skills in project management and leadership, and analytical skills. These capabilities are essential for effective planning, execution, control and troubleshooting during commissioning and start-up. Synopsis Chemitech has substantial experience of successfully executing such activities in timely, safe and cost-effective manner.

Chemical plant commissioning typically falls within three steps:

  1. Pre-commissioning: This stage involves activities that occur during the final stages of construction, including pre-functional test (PFT) inspections; end-of-construction punch lists and check sheets; factory and site acceptance testing of control systems; instrument loop checks and more.

  2. Commissioning: Sometimes referred to as “cold” commissioning, this second step (Specially for a chemical plant) involves running and testing the process without adding the chemicals or hazardous materials. pre-commissioning focusing on equipment, and commissioning focusing on the system.

Depending on the complexity of the project, commissioning can be executed on individual systems, groups of systems or even partial systems. The commissioning timeline is a function of construction progress, and a commissioning team may be required to modify system commissioning as systems reach construction completion.

Cold commissioning is typically executed by the owner with support provided by the commissioning team. The commissioning team can support the owner with planning and scheduling of activities, manpower requirements for contractor support, and by providing engineering calculations required for various commissioning tests. Some standard tests that may require engineering support and calculations include water system flushing, compressed air blows, temporary support of piping for testing, and steam blows.

  1. Startup: This final step is where the plant is finally brought into operation by the owner. During start-up, the commissioning team will provide engineering support as required by the owner. A successful commissioning effort generates site-specific knowledge that can be used by the commissioning team to assist in the startup. Some common support functions include operator systems training, process systems troubleshooting, lockout-tagout practices and other safe work procedures, and pre-startup safety review participation.

Personnel and User Training

  • Courses and training sessions for technical personnel and experts in construction, machinery, EMSR and automation

  • Training sessions for operators and users, as well as administration and logistics personnel

  • Courses on plant safety and responses to emergencies

  • Courses on particular uses

  • Courses on user documentation, operating handbooks, service and maintenance handbooks, as well as recognising and remedying failures.

  • Training at previously project site, class train, paper examination, training at current project site.