Integration Study of a Modification Project

In brownfield project development, Integration Study is one vital step which contributes to the success of a modification project. This study is required to evaluate the impact of modification to existing facilities in area of safety, process, installation, operation and maintainability point of view.  This integration study usually performed during conceptual stage and pre-FEED/Pre-Project  stage. Some main aspects will be evaluated during this integration study such as:

• Gap Analysis of updated referential and referential of the existing installation.
• Main equipment elimination and addition which has significant weight and significant impact to existing facilities layout.
• Construction methodology
• Requirement of production shutdown during construction.
• Major impact to existing process and safety shutdown system.
• Impact to existing utility demand.
• Impact to existing operating philosophy
• Impact to existing logistic
• And other aspects which may vary depend on the modification itself.

During conceptual study, the integration usually focuses on main critical aspects associated with several modification proposals. The objective is to classify concepts and justify the concept selected for the next engineering phases (Pre-FEED/Pre-Project). During this stage, main aspects which may become potential showstopper/significant issue will be highlighted and become justification for eliminating a modification option.

During Pre-FEED/Pre-Project, the integration usually focuses on main aspects with only one selected modification scheme. This study will produce a more accurate cost estimate, schedule planning and project scope of work. Integration study during this stage will be a basis for developing a Project Statement of Requirement (SOR).

We need to keep in mind that the level of integration study is not similar with basic or detail engineering study. For cost and schedule efficiency, we need to keep the level of study to be not too detail but without losing the essential aspects of the study itself.  For example, the integration study for structural aspect of a platform extension needs to be limited to general structure analysis, not producing specific reinforcement calculation notes or detailed drawings.

Since most of main aspects in the integration study are internal company hands on experience and knowledge, integration study during conceptual study and Pre-FEED is much recommended to be led and performed by internal engineering resources involving many stake holders inside company. Outsource engineering consultant might be required only for spot basis.