A framework for developing systems engineering management for process plant acquisition projects

Abstract

South Africa has a history of poor performance on process plant acquisition projects in the process industry that apply chemical processes within large processing facilities to convert raw materials such as crude oil into fuel and by-products. The most recent failures include the highly publicized Medupi and Kusile projects. This research is based on the acquisition or expansion of large process plants within petrochemical, mining, and energy, typically Systems of Systems integration projects. A significant component of their failings can be attributed to poor systems engineering and systems engineering management capabilities. Acquisition in the context of this study refers to all processes within the stage-gate project development model from project inception to the beneficial operation of the acquired facility. Due to a lack of systems and tools to guide the development of systems engineers and systems engineering managers within the sector, this research was undertaken to develop an industry-specific framework based on the INCOSE framework to support development and recruitment processes. A conceptual model derived from a literature survey was validated and improved with qualitative data gathered using structured open-ended interviews with industry specialists and experts from organizations within the petrochemical, mining, and energy sectors. Insights regarding current recruitment practices and development processes were analyzed to validate the need for a tool and develop an appropriate model for its application. Finally, the analysis and general causes of project failures validated the contents of the framework by highlighting critical competencies and traits required to succeed within the sector.