Hi Friends,
As such it is difficult to list out all engineering and
execution activities, however all out efforts have been made to assimilate major engineering and execution activities containing information in systematic manner for guiding the young professionals engaged in
engineering of Alumina Refinery Project as outlined here under-
A.
Pre-Project Activities
1.
Finalization
of Product mix
2.
Quality
specifications of products
3.
Preparation
of Conceptual Report
4.
Technological
testing of bauxite
5.
Site
selection and land acquisition
6.
Identification
of available infrastructure like roads, rails, rivers and port facilities
7.
Estimation
of Raw material consumption factors
8.
Estimation
of utilities requirement like steam, power, chilled water &compressed air
9.
List
of major equipment with broad specifications
10.
Estimation
of Capex and Opex
11.
Development
of Plot plan
12.
Preparation
of Feasibility Report
13.
EIA /
EMP Report
14.
Statutory
clearances for site
15.
Receipt
of Consent to Establish (CTE)
B.
Basic Engineering
1.
Process
Design Basis
2.
Fixing
the process & operating parameters
3.
Material
flow balance
4.
Thermal
energy balance
5.
Water
Balance
6.
Caustic
Balance
7.
Alumina
Balance
8.
Condensate
balance
9.
Development
of Overall Process Flow Diagram
10.
PFDs
for All Units
11.
P&IDs
for All Units
12.
Broad
specifications of major technological equipment
i.
Primary
& secondary crusher
ii.
Conveyors
iii.
Vibro-pulse
screens
iv.
Ball
mills
v.
Slurry
pumps
vi.
Heat
Exchangers
vii.
Autoclaves
/ Digesters
viii.
Flash
Tanks
ix.
Evaporators
x.
PHEs
xi.
Boilers
xii.
Compressors
xiii.
Cooling
Towers
xiv.
Rotary
Disc Filters
xv.
Rotary
Drum Filters
xvi.
Calciners
13.
List
of major equipment with motor ratings
14.
Specifications
of other process equipment
15.
Instrumentation
and control philosophy
16.
List
of cranes and hoists
17.
Sizing
of heat exchangers
18.
Sizing
of Desilicators
19.
Sizing
of Liquor decanters & washers
20.
Sizing
of Precipitators
21.
Sizing
of condensate & other liquid storages tanks
22.
Specifications
for liquor and water pumps
23.
Sizing
of pipelines
24.
Sizing
of valves
25.
Acid cleaning system for heat exchangers
26.
Chemical
cleaning system for precipitators
C.
Detailed engineering
1.
Preparation
of tender documents
2.
Development
of General layout of the plant
3.
Preparation
of shop layout
4.
Assistance
in evaluation of offers
5.
Assistance
in inspection of equipment
6.
Assistance
in procurement of plant & equipment
7.
SLD
for Power Control Centre (PCC)
8.
SLDs
for Motor Control Centre (MCC)
9.
Design
of Digesters
10.
Design
of Flash tanks
11.
Design
drawings for tanks and vessels
12.
Inspection
and expediting activities
13.
Drawings
for process & utility piping network
14.
Design
drawings for Civil & Structural Buildings
15.
Foundation
drawings for all equipment & facilities
16.
Certification
of bills payable to contractors and suppliers
D.
Construction activities
1.
Preparation
of schedule of activities
2.
Planning
for materials, machines and manpower
3.
Planning
of construction activities
4.
Appointment
of Competent Contractors
5.
Supervision
of construction at site
6.
Cost
& quality control during erection
E.
Assistance in Testing & Commissioning
1.
Checking
Mechanical completion
2.
Cold trial
run
3.
Hot trial
run
4.
Commissioning
of equipment
5.
Plant
commissioning procedure
6.
Performance
guarantee test
F.
Stabilization of plant
1.
Finalization
of process and operating parameters
2.
Guiding
the team for steady plant operation
G.
Quality control methodology
H.
Safety and Environmental Management & Control
Techniques
I.
Preparation of As-Built Drawings.
Hope, you will
realize the extent of efforts put by our team in preparing such exhaustive list
of information. The above list clearly indicates the volume of work associated in engineering and
execution activities involved in putting up any Alumina Refinery in any
geographical location across the globe. Our team will welcome your feedback and
suggestions in further improvement. Please feel free to contact us for
clarifications, if any.
Best regards.
Rajendra Kunwar
rajendra@ceti.co.in
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