King Fahad University of Petroleum & King Fahad University of Petroleum & MineralsMinerals

Term ProjectTerm Project

Expansion of Water Expansion of Water Treatment PlantTreatment Plant

Sagar M. Al-Anazi

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1. Introduction2. Information Phase3. Functional Phase 4. Creative Phase5. Evaluation Phase6. Development Phase7. Implementation & Presentation

Presentation OutlineCE

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Reverse Osmosis Process

Feed Pretreatment Process RO Process

Demineralization

ProcessCondensate Water Tanks

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The Existing Situation

The existing plant is unreliable plant and has the following problems:

1. Type of membranes (HFF) is obsolete. 2. There are reliability concerns.3. High maintenance cost comparing with other RO plant.4. More chemical consumption.5. The other water treatment plants (old plants) will be

demolished due to aging.

Information PhaseCE

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A company has decided to upgrade the existing water treatment plant the (RO Plant) to overcome the existing problems and to produce 1000 gpm industrial water instead of 400 gpm .

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• Expand the existing water treatment plant by providing 16 new RO Units.

• Use new type of membranes.• Minimize the chemical consumption.• The plant production should meet the

required water quality.

Information PhaseObjectives or required

Criteria

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The original Design

• Install additional pretreatments Equipments.

• Install 16 RO Units using SW Membranes to reduce water TDS to 20 ppm.

• Install additional 4 Deminalizers to reduce the TDS to less than 5 ppm.

• Install new Deaerator to remove gases.

Information PhaseCE

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Information Phase

ContactMajor PointsAESRO Vendor

SIDMASRO Vendor

CSDSaudi Aramco

Consultation Record

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Cost DataParticularUnit Price)$( Cost)$(

6 Pretreatments Filters

150,000900,000

16 RO Units250,0004,000,000One Deaerator500,000500,000

4 Deminilizers1,000,0004,000,000Chemical Injection Facilities

75,000150,000

Information Phase

Tot. Cost = $ 9,550,000

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Functional Phase

Identify the present Function

Verb Noun Provide Industrial Water

Support Operations

Verb Noun Produce Industrial Water

Support Operations

What does it now do?Item description:

What must it do?Objective or required

criteria:

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Functional Phase

WhyFunctionHowTo Support

Plant Operations

Produce industrial

Water

Expansion of the RO Plant

Functional Worksheet

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Creative Phase

• Use Sea water spiral wound membranes

• Eliminate Deminilizeras and related equipments.

• Eliminate Deareator.

Generate Ideas-:

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Evaluation PhasePotential Cost Benefit

Time to implement

Probability of implementation

Cost to develop

Use Sea water spiral wound membranes

Eliminate Deminilizeras

Eliminate Deareator

Tot. Rank

Feasibility Ranking

2 107710 98 810

10810

343926

213

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IdeaAdvantageDisadvantageRank

Use Sea water spiral

wound membranes

High water quality

TDS < 5 ppm

Required close monitoring

3

Eliminate Deminilizera

s

Reduction in the cost

Reduction in chemical

consumption

Increase the load on the membranes

1

Eliminate Deareator

Reduction in the cost

Increase the load on other

plants

2

Evaluation PhaseIdeas Comparison

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Evaluation Phase

A. Initial Cost

B. Operation & Maintenance

C. Reliability

D. Environmental Impact

How Important

3. Major Preference 2. Medium Preference

1. Minor Preference

Raw Score Assigned Weight

Criteria

Determining Weight for Evaluation

7

4

3

1

6

2

5

10

BCD A A-2 A-2 A-3  

B/C BB-3  

CC-2  

D 

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5EEEERank

 

4VGVGVGVG

 

3GGGG

2FFFF

1PPPP 

SUP TOT     

Idea 35EEEERank

 

4VGVGVGVG

 

3GGGG

2FFFF

2PPPP 

SUP TOT     

Idea 1 5EEEERank

 

4VGVGVGVG

3GGGG

2FFFF

1PPPP 

SUP TOT     

IdeasWT

Assigned Value

Total  7 4 3 1

Initial Cost

Oper & Maint.

Envir. Impact

Reliability

Use Sea Water SW Membranes

Idea 2Eliminate

Deminilizers

Eliminate Deareator

Evaluation PhaseEvaluation

Matrix

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42

56

47

Development PhaseAdditional Information

Additional information was collected to develop the alternatives. 1. Equipments specifications.

2. VE team consulted RO manufactures like Toray (website) .

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The Initial Cost of Deminilizer = $ 1,000,000Annual maintenance cost = $ 13,000Salvage value = $ 30,000Interest rate = 5%Service life = 20 years

Then, P = 1000,000+ 13000(12.4622) – 30,000 (0.3769) = $ 1,150,702.0

The original Life cycle of Deminilizers

1,000,000

30,000

13,000

200

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Original: Install 4 Deminilizers.Proposed: Eliminate the deminilizers

$ 4,000,000

Total CostItem

$ 0

Saving in Initial Cost = 4,000,000

Original Life cycle cost = 4,602,808Proposed Life cycle cost = $ 0Saving in Life cycle cost = 4,602,808

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The Initial Cost of Deaerator = $ 500,000Annual maintenance cost = $ 6,000Salvage value = $ 12,000Interest rate = 5%Service life = 20 years

Then, P = 500,000+ 6000(12.4622) – 12,000 (0.3769) = $ 570,251.0

The original Life cycle of Deaerator

500,000 12,000

6,000

200

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Original: Install a DeaeratorProposed: Eliminate the deaerator

$ 500,000

Total CostItem

$ 0

Saving in Initial Cost = 500,000

Original Life cycle cost = $ 570,251.0Proposed Life cycle cost = $ 0Saving in Life cycle cost = $ 570,251.0

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The Initial Cost of RO Unit = $ 250,000Annual maintenance cost = $ 8,000Salvage value = $ 9,000Interest rate = 5%Service life = 20 years

Then, P = 250,000+ 8,000(12.4622) – 9,000 (0.3769) = $ 346,306

The original Life cycle of RO Unit

250,000 9,0008,000

200

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The Initial Cost of RO Unit = $ 270,000Annual maintenance cost = $ 8,000Salvage value = $ 9,000Interest rate = 5%Service life = 20 years

Then, P = 270,000+ 8,000 (12.4622) – 9,000 (0.3769) = $ 366,306

The proposed Life cycle of RO Unit

270,000 9,0008,000

200

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Original: Install 16 RO UnitsProposed: Install 16 RO Units and Use Sea Water Membranes

$ 4,000,000

Total CostItem

$ 4,800,000

Increase in Initial Cost = $ 800,000

Original Life cycle cost = $ 346,306/Unit = $ 5,540,896Proposed Life cycle cost = $ 366,306/unit = $ 5,860,896

Increase in Life cycle cost = $ 320,000

Saving in Initial Cost = $ 4,180,000 = 44% Reduction

ParticularUnit PriceCost)$( 6 Pretreatments

Filters 150,000900,000

16 RO Units270,0004,320,000Chemical Injection

Facilities75,000150,000

Proposed Cost = $ 5,370,000 Original Cost = $ 9,550,000

Development PhaseCE

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Saving

Value Study ProposalVE team recommended the following proposal to design the water treatment plant:-

1. Use sea water membranes.2. Eliminate the deminilizers. 3. Eliminate the deaerator.

The final product of sea water SW membranes will meet the requirement of water quality (TDS will be less than 5 ppm). Also, the new plant production which is 1000 gpm will not be affected by this change.

Using sea water membranes will increase the initial cost of the membranes by $ 800,000 but will eliminate the need for deminilizers and dearteator.

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Proposal Advantages 1. Reduce the initial cost

2. Eliminate unrequited equipments.

3. Minimize chemicals consumption.

4. Reduce the maintenance cost.

5. Safety.

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1. How should it be implemented? VE proposal will be discussed with the engineering

and project team to remove any roadblocks prior to management presentation

2. What should be changed and in what sequence? The proposed case will be discussed with

engineering team.

3. Who should do it? Engineering department.

4. How long should it take? 5 months

5. Any deadline required? Before issuing the IFC package.

Implementation PhaseCE

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Thank youQ & ACE

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