Engineers and scientists involved in research and design, or those who operate or use the results of pilot plant or laboratory units, will learn the essential steps for selecting, designing, building, commissioning, and operating these units. They will gain the ability to evaluate their options based on their organization’s specific needs and understand the different approaches available to save time and reduce costs. Less experienced personnel can use this course to become more proficient in their work, while more experienced personnel will benefit from a comprehensive review of the entire process. All participants will gain insight into the advantages and disadvantages of various approaches.
This detailed course is designed for engineers, scientists, operators, and managers who build, design, operate, or support pilot plants or laboratory units for research and development. It provides a comprehensive overview of all stages of the process—from determining what type of unit best meets the organization’s goals, to selecting the most effective design approaches for specific needs. The course also covers how to develop accurate cost estimates, determine realistic project timelines, and identify the most efficient and effective methods for commissioning the unit. It explores strategies for implementing cost-effective maintenance programs and addresses operational issues that can enhance unit performance.
The instructor draws on 49 years of experience to highlight practical challenges that must be addressed to ensure a unit’s success. Practical solutions are suggested, and the advantages and disadvantages of various approaches—many of which are less obvious than they may initially appear—are discussed.
The course also examines whether a pilot plant or laboratory unit is needed, and if so, how to determine which features are essential versus optional. It offers methods to distinguish between critical requirements and “nice-to-have” features. In addition, it provides valuable information to help organizations assess the accuracy of their cost estimates and schedules, or evaluate the quality of a contractor’s proposal. Commissioning approaches are discussed in detail and plans presented to help this go faster.
By the end of this course, you will be able to:
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Define and plan a pilot plant program — determine whether a pilot or laboratory unit is needed, establish clear goals, and develop a strong design basis.
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Select effective design strategies — understand how pilot plants differ from full-scale process plants, minimize risks, and apply proven approaches for design and construction.
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Estimate costs and develop project schedules — create accurate cost estimates and timelines, understand contingency and accuracy levels, and evaluate contractor proposals.
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Design safe and efficient pilot plant spaces — choose between building layouts, containment cells, open bays, and laboratory configurations to optimize safety and functionality.
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Evaluate control system options — select, size, and implement control and safety systems that balance performance, reliability, and cost.
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Manage start-up and commissioning — plan and execute effective start-up sequences, perform calibration and testing, and ensure smooth transitions to operation.
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Implement cost-effective maintenance programs — develop strategies to minimize maintenance costs, balance in-house and contracted support, and maintain reliability.
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Optimize ongoing operations — establish organizational models, handle modifications, manage change, and ensure continuous improvement in performance.
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Apply practical experience and lessons learned — benefit from real-world examples drawn from nearly five decades of pilot plant design and operation experience.
Engineers, scientists, operators, and managers who build, design, operate, or support pilot plants or laboratory units for research and development.
1. Defining a Pilot Plant Program
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What is a pilot plant?
-
Defining the goals of the pilot plant
-
Identifying key issues
-
Selecting the appropriate strategy
-
Developing a design basis
-
Prototype concerns and implications
2. Pilot Plant Design Issues and Strategies
-
Differences from process plants
-
Prototype concerns
-
Design approaches
-
Minimizing downside risk
-
Design and construction options
-
Guidelines for successful contracting
-
Continuous vs. batch systems
-
Attended vs. unattended operation
-
Design hints
3. Types of Space Suitable for Pilot Plant Operations
-
Separate buildings
-
Containment cells
-
Open bays
-
Hoods and laboratory areas
-
Estimating pilot plant space requirements
4. Pilot Plant Cost Factors
-
Practical effects of budget constraints
-
Estimating design and construction costs:
-
Similarity (standard)
-
Similarity (adjusted)
-
-
Cost ratios:
-
General
-
Specific
-
-
Detailed labor and materials:
-
Detailed labor with materials added
-
Detailed materials with labor added
-
Detailed labor and materials
-
-
Issues and concerns
-
Contingency
-
Accuracy
5. Schedule Factors
-
Major areas of concern
-
Guidelines for effective scheduling
-
Crash program risks
-
Approaches to minimize problems
-
Technology implications
6. Pilot Plant Control Systems
-
Types of control systems
-
Estimating system size
-
Maintenance and reliability
-
Contracted vs. in-house maintenance
-
Control system placement options
-
Guidelines for successful control rooms
-
Control vs. safety systems
7. Pilot Plant Start-Up
-
Differences from major process unit start-up
-
Optimizing start-up efforts
-
Start-up resources
-
Start-up sequences
-
Equipment
-
Calibration
-
Turn-key vs. in-house start-up
-
Flushing
-
Leak testing
8. Pilot Plant Maintenance
-
Advantages of good maintenance
-
Types of maintenance
-
How to minimize maintenance costs
-
Typical maintenance costs
-
In-house vs. contracted maintenance
9. Operations
-
Operating organization models
-
Modifications vs. new construction
-
Management of change
-
On-line maintenance
-
Coverage and shift issues
-
Operational support
10. References
11. Q&A
1. Defining a Pilot Plant Program
-
What is a pilot plant?
-
Defining the goals of the pilot plant
-
Identifying key issues
-
Selecting the appropriate strategy
-
Developing a design basis
-
Prototype concerns and implications
2. Pilot Plant Design Issues and Strategies
-
Differences from process plants
-
Prototype concerns
-
Design approaches
-
Minimizing downside risk
-
Design and construction options
-
Guidelines for successful contracting
-
Continuous vs. batch systems
-
Attended vs. unattended operation
-
Design hints
3. Types of Space Suitable for Pilot Plant Operations
-
Separate buildings
-
Containment cells
-
Open bays
-
Hoods and laboratory areas
-
Estimating pilot plant space requirements
4. Pilot Plant Cost Factors
-
Practical effects of budget constraints
-
Estimating design and construction costs:
-
Similarity (standard)
-
Similarity (adjusted)
-
-
Cost ratios:
-
General
-
Specific
-
-
Detailed labor and materials:
-
Detailed labor with materials added
-
Detailed materials with labor added
-
Detailed labor and materials
-
-
Issues and concerns
-
Contingency
-
Accuracy
5. Schedule Factors
-
Major areas of concern
-
Guidelines for effective scheduling
-
Crash program risks
-
Approaches to minimize problems
-
Technology implications
6. Pilot Plant Control Systems
-
Types of control systems
-
Estimating system size
-
Maintenance and reliability
-
Contracted vs. in-house maintenance
-
Control system placement options
-
Guidelines for successful control rooms
-
Control vs. safety systems
7. Pilot Plant Start-Up
-
Differences from major process unit start-up
-
Optimizing start-up efforts
-
Start-up resources
-
Start-up sequences
-
Equipment
-
Calibration
-
Turn-key vs. in-house start-up
-
Flushing
-
Leak testing
8. Pilot Plant Maintenance
-
Advantages of good maintenance
-
Types of maintenance
-
How to minimize maintenance costs
-
Typical maintenance costs
-
In-house vs. contracted maintenance
9. Operations
-
Operating organization models
-
Modifications vs. new construction
-
Management of change
-
On-line maintenance
-
Coverage and shift issues
-
Operational support
10. References
11. Q&A
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