Projen’s GlaxoSmithKline condenser project involved the replacement of forty 12-year-old glass condensers tightly housed in nine chemistry pilot plant (CPP) modules at the R&D center in Stevenage, Hertfordshire. The replacements are made of a safer, more robust metal design to ensure the continued production of new chemicals. The CPP modules represent more than half of the worldwide pilot plant capacity used to supply drugs for clinical trials.
The existing piping and layout arrangement in the modules is complex, space is at a premium, and a lot of equipment and piping had to be temporarily moved. Critical success factors included:
A photogrammetric approach was employed to develop 3D models of the modules using dedicated software and AutoPLANT. This aided visualization of the phased demolition and construction, and assisted stakeholder communication. The software has also been used to generate detailed isometric drawings of the pipe routes. The model has been shown to be accurate to within a few millimeters, minimizing rework of pipe spools and components.
Suppliers and construction management were involved in the front-end development and model reviews, which shortened the design phase, minimized risk, and maximized opportunities.