Large International Chemical Company

Value Drivers: Revamp, Clash Detection, Reducing Re-Work

Quantapoint Situation

One of the largest producers of ethylene, polypropylene, and polyethylene in the world today and a leading producer of polypropylene, oxygenated chemicals,

performance polymers, and wire and cable resins and compounds was focusing on large, efficient, low-cost facilities to improve its cost structure and help the company produce higher value EO derivatives. This is a philosophy that extends too many parts of its business, including project execution.

Challenge

The chemical company proposed a revamp of multiple process heaters at one of its manufacturing facilities. Due to corrosion and the age of the equipment, the project required that the upper portion of an existing 10-story operating unit consisting of 23 process heaters be removed and replaced. Due to lack of as-built documentation, safety concerns, project schedule and construction rework on previous projects, Quantapoint was selected to reduce risk and achieve project goals.

Solution

Quantapoint combined technology proven work processes to capture existing piping and fittings, process heaters and other equipment, structural steel, electrical and instrumentation, and other unit features. We then integrated our laser data with CAD to help ensure clash-free designs.

Quantapoint1Results

Quantapoint is typically able to reduce rework by 80% – measuring individual events and not a percentage of the total installed cost (‘events, not percents’), saving millions of dollars with a greater than 1,000% return on investment. Typical benefits to the customer included the following:

  • Reduced costs from 75% fewer field trips, 50% fewer fit-up welds and field changes and less maintenance
  • Optimized schedules by reducing data collection time by 80%, revamp time by 1 day from better construction  lans and design time by 30% from access to better information.
  • Increased quality due to 75% fewer field changes, 100% shop prefabrication and better pipe routing plans.
  • Improved safety from 50% fewer people in the field, 75% less scaffolding and 50% less hotwork.

Major Chemical Company (PDF)