Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities
A globally recognized chemical producer that had recently acquired a legacy plant used to produce highly hazardous agricultural chemicals turned to aeSolutions’ multi-disciplinary capabilities for a comprehensive solution to bring their legacy plant into compliance. The client was faced with a tight schedule to meet their corporate process safety standards through a functional safety upgrade, with the goal of bringing the facility into PSM OSHA 1910.119 compliance.
Once awarded the project, aeSolutions successfully delivered the client’s FEL3 and Detail Design goals. As part of the FEL3 project, aeSolutions collaborated with the client to establish an estimate basis. This helped ensure the accuracy of the total installed cost estimate, with the project coming in slightly under the estimated value. The success and quality of this project’s outcome serves as an example of aeSolutions’ unrivaled capabilities as a comprehensive lifecycle solutions provider within the industry.
Challenge
This complex project posed numerous challenges during the Front-End Loading (FEL) phase for the client’s newly acquired agricultural chemical production facility. The legacy facility did not meet the client’s corporate process safety standards, nor was it PSM OSHA 1910.119 compliant.
aeSolutions was tasked with providing Front End Loading (FEL) level III engineering design services for the Process Control Technology (PCT) discipline. Basic design for Phase 1 at the legacy facility was to cover a kiln, a hydro clarifier, a waste heat boiler, and multiple coal mills.
The final challenge was developing an accurate total installed cost estimate that the client then used to secure funding.
Solution
• By implementing processes and project sponsorship to promote efficient communication between the client’s remote stakeholders and the management team of the legacy facility, aeSolutions was able to foster an environment that proved to be essential in meeting the client’s goals of achieving PSM OSHA 1910.119 compliance within their schedule.
• aeSolutions successfully provided cross-discipline deliverables within the client’s timeline, while accommodating several scope revisions from the client.
• aeSolutions’ recognition of the importance of not only being aware of a project’s information but having the experience to also know where the information needs to flow helped facilitate the overall success of the project.
• By utilizing aeSolutions’ team of experienced subject matter experts across multiple disciplines, we were able to provide the level of knowledge, understanding, competency, and dedication required to meet the client’s strict requirements.
• By educating the client’s operations team about the rationale of actions throughout the project, aeSolutions helped to facilitate better alignment between the client’s corporate/capital project team and the facility operations team.
• Through the meticulous attention to detail and quality of services provided, aeSolutions’ was able to bring a highly hazardous chemical production facility into PSM OSHA 1910.119 compliance.
- aeSolutions worked closely with the client to establish a comprehensive and accurate total installed cost estimate for the project.
• The accuracy of aeSolutions’ estimate meant that the client did not have to request supplemental funding, that no change orders were required, and that the project was ultimately completed slightly under the total installed cost budget.
• Adherence to the client’s aggressive timeline relied on the versatility of aeSolutions to integrate with the client’s newly implemented document control system. This adaptability proved to be an integral part of aeSolutions’ ability to complete the project roughly two months ahead of schedule — relative to other groups that were working in parallel.
• In the face of the complexities and evolving requirements of this project, aeSolutions was able to deliver FEL3 and the Detailed Design results that the client was thrilled with.
• aeSolutions’ assignment of appropriate resources based on alignment with the requirements of the project’s complexity and risks — contributed to the high productivity rate realized during this project.
Results
This project’s successful execution serves as a textbook example of the results clients hope for. From the initial development of front-end loading (FEL3), a highly accurate total installed cost estimate, and Detail Design deliverables, every aspect of our contribution to this project helped bring the client’s legacy facility into compliance with PSM OSHA 1910.119 regulations as well as the client’s own corporate safety standards. The aeSolutions multi-disciplinary team and their ability to adapt to the client’s evolving needs played a pivotal role in achieving the project’s success. By integrating seamlessly with the client’s document control system and maintaining strict adherence to safety and regulatory requirements, aeSolutions delivered results that represented an — according to the client — excellent quality of deliverables.
Industry: Hazardous Agricultural Chemical Production
Geography: West
Unit Operation: Front End Loading Level III (FEL3), Detail Design