12013889
Description
Flashcards by Márton András Nagy, updated more than 1 year ago
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Created by Márton András Nagy
about 6 years ago
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| Question | Answer |
| What do you understand by plant? | A plant is a system for the realization of a physical, chemical or biological process. The aim of the process is to convert raw materials into a desired product. The plant consists of equipment, piping and instrumentation |
| What do you understand by equipment? | Equipment means reactors, columns, heat exchangers and so on. The main equipment of a plant is often a reactor. In the reactor, chemical or biological reactions are performed. In order to get a high yield and selectivity, the process variables such as temperature, pH-value or medium composition have to be maintained at an optimum level |
| What are the objectives of the following company: Engineering company Give an example | Objective: Design and construction of process plants (turn key plants) Examples: Jacobs Engineering, Pasadena, California LSMW, Stuttgart, Germany |
| What are the objectives of the following company: Equipment manufacturers Give an example | Objective: Development and manufacturing of equipment Examples: Sartorius Stedim Bioengineering GE Healthcare |
| What are the objectives of the following company: Chemical or pharmaceutical companies Give an example | Objective: Development and manufacturing of chemical and pharmaceutical products Examples: BASF Roche Nestle |
| What do you understand by feasibility study? | A feasibility study is a preliminary study undertaken to evaluate a project's viability. The term feasibility study can also refer to the resulting document. The outcome of the feasibility study is used to make a decision whether to proceed with the project, or drop it. |
| What information is provided by the market analysis? | Market volume Market share Market growth Market price |
| Name three methods which are used for a market analysis? | Utilization of market studies Statistical year books Customer interviews |
| Cost correlation | C=c*x1^(m1) C=c*x1^(m1)*x2^(m2) C=Equipment cost x1,x2=capacity parameter c,m1,m2=constant |
| 2.3 Degression exponent | C=C0*(x/x0)^m C=Eq. cost C0=Eq. cost of base size x=capacity parameter x0=cap. param. of basic size m=degression exponent |
| 2.4 Cost indexes | C=C0*(I/I0) C=cost of eq. at present time C0=cost of eq. at previous time I=cost index at present time I0=cost index at previous time |
| 2.5 Factored estimate procedure | Cp=Ceq*f Cp=total plant cost Ceq=total costs of major equipment f=multiplication factor |
| Name the two methods used to estimate the profitability. When are they applied? | Cost comparison, is applied to evaluate different alternatives for the same objective or to check if a modification is economical Profitability is used to evaluate whether its economical to build or operate a plant Profitability=(Profit/capital)*100% P=(S-C)/(Cp+Cw)*100% |
| What is the objective of process development? | The objective of process development is to establish a process to produce a desired product in an industrial scale taking into account economic, ecological and safety boundary conditions. |
| What are the two objectives of product characterization? | Identification of the product characterization of the product The identification of the product is like a fingerprint of the product and can be used later on to clarify the reasons for problems during comiss. and operation of the plant |
| Name five types of product properties | Biological properties Chemical properties Mechanical properties Thermal properties Safety properties Toxicity properties |
| What two decisions are influenced by the product behavior? | Product properties -> Behavior Equipment selection Operating conditions |
| What is the objective of equipment selection? | The objective of equipment selection is to choose the most suitable equipment for an individual unit operation |
| Name the essential criteria for equipment selection | Operating data Product data Equipment data Material data Laws and regulations |
| Name three methods for equipment selection | Experience Decision trees Decision charts Expert systems |
| What are the two objectives for equipment design? | Determination of the equipment size Determination of the operating conditions |
| Name the essential criteria for equipment design? | Operating data Product data Equipment data |
| Name the to methods for equipment design? | Approximate design early in proc.dev., quick to make, limited data needed Detailed design advanced stage in p.d., based on models, made on computers reliable data needed |
| What is the objective of conceptual design? | The objective of conceptual design is to develop a concept for the plant to be built. Potential solutions e.g. alternative sites for the plant are evaluated and a specification for the plant is developed. Provides the basis for the basic design |
| Name three documents produced throughout conceptual design? | Block flow diagram Functional layout Personnel and material flow Process simulation Cost estimation |
| What is a block flow diagram? | BFDs are used for illustrating a process or plant in a simple form. They consist of rectangular blocks connected by lines. Blocks represent process steps, lines represent material and energy flows |
| Drawing of a simple Block Flow Diagram |
Image:
Bfd (image/gif)
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| What is the objective of basic design? | Objective is development of a basic design for the plant to be built. It's based on conceptual design, focuses on type and dimensions of major equipment, design temperatures, pressures, materials. Establishment of plant layout |
| Name three documents produced throughout basic design | Process flow diagram Equipment list Process data sheets Plant layout Utilities distribution scheme Electrical equipment list Soil report |
| What is a process flow diagram? (What is it used for? What does it consist of?) | PFDs are used for illustrating a process in more detail. It consists of standardized symbols which are connected by lines. Symbols represent major eq. (reactor, pump, heat exch.) Lines represent material and energy flow. |
| What document is used for the specification of equipment? | Process data sheets The size of equipment depends on flow rates or amounts of material or energy to be handled. These design data are entered in process data sheets, which contain all relevant specifications for the equipment |
| What is the objective of detail design? | In detail design the project team prepares detailed flow sheets, equipment drawings, eq. data sheets, piping drawings, piping specifications and layouts so actual production step can begin |
| Name three documents produced throughout detail design? | Piping and Instrumentation Diagram Piping specification Final plant layout Detailed flow sheets Detailed eq. data sheets |
| What is a piping and instrumentation diagram? (What is it used for? What does it consist of?) | P&ID is based on PFD. It represents the technical realization of a process. It consists of graphical symbols for eq. and piping together with graphical symbols for measurement and control functions |
| Meaning of letter codes for instrument functions: TI PDI TIC PDIC | Temperature Indication Pressure Difference Indication Temperature Indication Controlling Pressure Difference Indication Controlling |
| What type of drawing is used to depict pipe runs? | Piping drawing that show both the geometry of the run and its location in the plant. Diagram with a single pipe run and its components, along with measurement and control devices and piping supports. |
| What are the four main tasks of a project manager throughout project execution? | Establishment of project organization Coordination of subtasks Direction if subtasks Monitoring and control of subtasks |
| Describe a structural organization | The structural organization illustrates the departments and teams of a company and the relationships between them. |
| Describe process organization | The proc.org. illustrates the work flow of a business process. The work flow consist of an input, activities and an output |
| Explain the three types of structural organizations | Functional organization: structured according to functions, well suited for companies with a single or dominant core product Divisional organization: number of self-managed divisions, each operates as a profit center (business units). Based on product or market. Centrally provided financing and HR. Matrix organization: Overlay of the two previous, combines product with geographical. Employees have two bosses. |
| What two types of project organizations can be distinguished? | First for large projects (PO1) Project manager with executive authority. P members are exclusively assigned to the P team for the duration of the P. P members report to PM Second for smaller projects(PO2). P members are not exclusive to the P team. PM has dotted line authority. P members report to their department M. |
| Name three consequences of delays | Req. of additional personal resources Incurring of additional costs Payment of penalties Claim to consequential damages Loss of reputation |
| What is a network diagram? | Illustration of a complex project in form of a netwrok(arrows and nodes), which can be used for a structural nalysis and optimization of the work flow |
| What are the two phases in network planning? | Planning phase: breakdown of the overall project into smaller activities and definition of the dependencies between activities Scheduling phase: Estimation of the durations and finish dates for overall activities |
| Three most important network diagram methods? | CPM Critical path method (activity on arrow) MPM Meta potential method (activity on node) PERT Program evaluation and review technique (event on node method) |
| What are the two main consequences of cost overruns? | Reduction of profit of engineering company building the plant Reduction of profit of manufacturing company operating the plant Procurement has a key role in lowering costs. |
| Two methods of cost control | Cost tables for the manufacturing and installation of eq. Cost diagrams |
| Three types of documentation for the plant | Execution (for technical and commercial execution) Technical (about design and function of indiv. eq. and total plant) Operating (docs about operation of indiv. eq. and total plant) |
| What is the objective of construction? | The objective of construction is to build a plant. It includes all activities from excavation to mechanical completion |
| What are the main tasks during construction of a plant? | Procurement of eq., materials, services Construction of the building Erection and installation of eq. Installation of electrical system, measuring and control equiment Functional test of equipment |
| Main tasks of procurement? | Purchase of equipment, materials, services Expediting during fabrication of eq. (Cost Time Quality) Shipping of eq. and materials to construction site |
| What are the three basic types of shipping? | Land, Sea and Air. Land- Trucks, Train- versatile Sea still requires land transport (harbor)- cheap Air also requires Land transport (Airport)-quick |
| Mechanical completion | When functional tests have been successful, mechanical completion is achieved. Generally, a plant is mechanically completed when subsequent commissioning will not be delayed or disrupted by installation work and that the safety of the plant is guaranteed. |
| What is the objective of commissioning? | To assure the proper function of the plant and that the contractual guarantees are achieved. It includes all activities from mechanical completion until hand over of the plant. |
| Main tasks during commissioning of a plant? | Test run of eq. with water (cold comiss.) Test run with product (warm comiss.) Test run complete plant Proof of compliance with guarantees Training personnel |
| What is a contract? | A legally binding exchange of promises or agreements between parties that will be enforced by law |
| What types of contracts can be distinguished according to contractual obligations? | Sales contract (Seller-Buyer) Rental or lease (Lessor - Lessee) Loan contract (Lender - Borrower) Employment contract (Employer-Employee) Work contract (Contractor-Buyer) |
| What types of contracts can be distinguished according to the scope of work? | Consulting contract Engineering contract Supply contract Construction contract Commissioning contract Service contract License contract |
| What types of contracts can be distinguished according to the mode of payment | Lumpsum contract Target cost contract Cost contract Measure and value contract |
| Elements of a contract | Names, addresses, roles of parties Preamble Deadlines Insurances Prices, terms of payment Warranties Penalties Duration of contract Termination of contract Confidentiality Signatures |
| What are the two possible conclusions of a contract | Contract signed by all parties (few disagreements) Offer-order-order confirmation (more disagreement) |
| Two kinds of warranties for a process plant | Process warranty : assurance of defined processes (Production capacity, Product quality, energy consumption) Mechanical warranty: Assurance of function of parts (excluding wear parts) during warranty period (limited usually 12 months max 18) |
| Name three elements which a notification of defects shall contain | Description of defect Request to remedy the defect Time limit for remedy of said defect |
| Three possibilities to protect an engineering company against inability of payment | Advance payment Letter of credit Export credit guarantee |
| How to avoid currency risk | Hedging currency risks (exchange rate guarantee) |
| What do you understand by quality assurance system | QAS cover all organisational and technical elements needed to achieve required quality Requirements for QAS are defined in standards like ISO 9000 - ISO 9004 Quality of product not only after production, but throughout entire production |
| Name five elements of a quality assurance system | Management responsibility Quality system Contract review Design Control Document control Product ID and Trace Process Control Inspection and testing Quality records Training |
| Extend these abbreviations: QMS QA QC SOP FDA EMEA | Quality management system Quality assurance Quality control Standard operating procedure Food and Drug Administration European Medicines Agency |
| Extend these abbreviations: GMP cGMP GAMP GLP GCP | Good Manufacturing Practice current Good Manufacturing Practice Good Automated Manufacturing Practice Good Laboratory Practice Good Clinical Practice |
| What do you understand by GMP | GMP is a term that is recognized worldwide for the management and control of manufacturing food and pharmaceutical products. It consists of a set of principles and regulations that are followed by manufacturers of food and pharma. products in order to ensure high quality |
| What do you understand by validation | Documented verification that a process, operated within the established parameters, is performing effectively and is reproducible in order to produce an intermediate or active pharma. ingredient meeting its predetermined specifications and quality attributes |
| What do you understand by qualification | Documented verification that an equipment or system is properly designed (DQ), properly installed (IQ), works correctly (OQ) and actually leads to the expected result (PQ) |
| What three types of validation can be distinguished according to the time of execution? | Prospective validation Concurrent validation Retrospective validation |
| Six steps of validation | Validation master plan (VMP) Risk analysis (RA) Design Qualification Installation Qualification Operation Qualification Performance Qualification |
| Extend thee abbreviations VMP RA DQ IQ OQ PQ | Validation Master Plan Risk Analysis Design Qualification Installation Qualification Operating Qualification Performance Qualification |
| What is a validation master plan? | The VMP provides the essential framework for performing the validation process it includes: Steps of validation Allocation of responsibilities Establishment of time-schedule Organisation of documentation |
| Objective of risk analysis | To identify critical process steps an parameters, and estimate their impact on product quality FMEA (failure mode and effect analysis) RPZ=AxBxE Risk priority number= likelihood of appearance*Importance of system*Likelihood of discovery |
| Objective of design qualification | Documented verification that the proposed design of an equipment or system is suitable for the intended purpose |
| Objective of Installation Qualification | Documented verification that the equipment or system, as installed or modified, complies with the approved design, the manufacturers recommendations and/or user requirements |
| objective of Operation Qualification | Documented verification that the equipment or system, as installed or modified, operates as intended throughout the anticipated operating ranges |
| Objective of Performance Qualification | Documented verification that the equipment and systems, as connected together, perform effectively and are reproducible, based on the approved process method and specifications |
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