epc project execution orientation course

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© 2015 – Hervé Baron

The execution of a Complex Project… a guided tour

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The actors

Impossible d’afficher l’image.

The COMPANY

“Client” The EPC Contractor

The suppliers

The sub-contractors

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Conceptual evaluation + Pre-Project

By COMPANY

Basic Engineering By ENGINEERING

Project Execution by EPC CONTRACTOR

Sanction Sanction

The phases

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Design Procurement Manufacturing Shipping

Installation Construction & erection Inspection & tests Hand-over

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The multiple sides of a Project

Hum

an Resources M

anagement

Project Control

PROJECT

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Engineering Sub-Contractor (India) Detail Engineering (part)

Shipyard (Korea) Hull Engineering & Fabrication

Shipyards (Singapore & Malaysia) Topsides Fabrication & Integration

Home office (Paris) •Project management •Detail Engineering (part) •Procurement

Satellite office Detail Engineering (part)

Fabrication yard (Nigeria): Fabrication (part)

Offshore (Nigeria): Installation, commissioning, start-up

The multiple sites of a Project

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Project

Engineering Procurement Construction

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Process facilities:

Feedstock and products flow

Feedstock composition

Battery limit conditions

Equipment Spare

Performance:

Products specifications

Energy efficiency, emissions

Utilities:

Electric power supply

Other utilities

Systems:

Process control

Fire/gas alarm

Public address, LAN, PABX

Infrastructure:

Administrative and technical buildings

Control room

Access road

Site fencing, gates, check point

Design criteria:

% of over design

Environment data:

Min/max temperature

Rain/snow fall

Wind

Geological conditions

Applicable codes and standards:

International standards

Local rules

0 5

10 15 20 25 30 35 40 45 50

-85 -80 -75 -70 -65 -60 -55

Pre

ssu

re (

ba

r)

The facilities design basis

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Engineering Documents for Purchase:

bill of quantity & specification

Documents for Construction:

Construction drawings & specifications

Design basis:

- Functional requirements

- Client specifications

- Design codes

Engineering in the Project

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Project

Engineering

Instruments& Control

Layout & Piping Process Electrical Equipment Civil Safety

Procurement Construction

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Process simulations

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Heat & Material balance

Thermodynamic calculations

Process Flow Diagram (PFD)

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Equipment list

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Equipment duty

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Process data sheet

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Process Flow Diagram (PFD)

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Piping & Instrumentation Diagram (P&ID)

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Process control

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Emergency shut down

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Emergency relief

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Operating manual

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Project

Engineering




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Rotating machinery

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Pressure vessels

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Heat exchangers

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Packages,

Fired Equipment

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Process data sheet

Mechanical data sheet

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Material Requisition

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Project

Engineering




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Fire fighting

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Passive fire protection

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Fire & Gas detection layout

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Environmental Impact Assessment

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Project

Engineering




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Equipment supporting structures

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Piping supporting structures (pipe-racks)

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Structural design

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Structural drawings

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Architectural drawings

Equipment layout drawing

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Project

Engineering




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Layout/

principles

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Layout/consideration for all networks

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General Plot Plan

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Piping Layout drawing

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3D modelling

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3D model review

3D model clash check

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Piping Design

Design code for Process plants: ASME B31.3

)(

PY 2SWED * Pt+

=

P design pressure D (outside) diameter S stress value for material as per table in ASME B31.3 W weld joint reduction factor – for long term strength of weld at elevated temperature E quality factor, from table in ASME B31.3 (1 for seamless, 0.85 for ER welded pipe, etc.) Y coefficient from table in ASME B31.3 (from 0.4 to 0.7 depending on material and temperature)

To the above calculated thickness shall be added: - The corrosion allowance, e.g., 3 mm - The manufacturing tolerance: 12.5%

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Thickness (mm) Number of passes

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Isometric drawing

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Piping Pre-fabrication

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Piping General Arrangement drawing

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Standard Pipe Support drawings

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Material Selection

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Material Specification

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Project

Engineering




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Instrument data sheet

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© 2015 – Hervé Baron Process Control System

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System architecture drawing

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Mechanical Equipment Control

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PT JB

Process line

Marshalling

cabinet

Controller

cabinet

Instrument room Control room

VDU

CPU

LAN Secondary cable

Multi cable

The instrumentation hardware

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Building detail drawing/Telecom and PAGA layout

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Cable routing drawings

Cable list

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© 2015 – Hervé Baron Cable routing inside technical rooms

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Project

Engineering




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Electrical consumers list

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Electrical Load Summary

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Electrical distribution

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General One Line Diagram

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Generators

Switchgear

Transformer

Equipment

specification

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Electrical equipment layout

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Electrical Control System

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Process design

PFDs

H&M balance

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Process design

PFDs

H&M balance

Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

Process data sheet

Equipment specification

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Process design

PFDs

H&M balance

P&IDs

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Process design

PFDs

H&M balance


P&IDs

Piping

Instrumentation

Layout

Civil

Electrical

Process data sheet


Vendor drawings

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Engineering work sequence

Extract from the book: ”The Oil & Gas Engineering Guide”, Hervé Baron, Editions Technip, 2015, page 209

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Typical 3 year EPC Project Engineering schedule

PR = Process, EQ = Equipment, PL = Plant Layout, PI = Piping, I&C = Instrumentation & Control, EL = ELectrcial, HSE = Safety & Environment, CIV = Civil


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Process design

PFDs

H&M balance


P&IDs

Piping

Instrumentation

Layout

Civil

Electrical

Process data sheet


Vendor drawings

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Vendor Instrumentation &

Control

Electrical

Layout

Civil

Piping Process

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Vendor Instrumentation

& Control

Electrical

Layout

Civil

P&ID

Functional analysis

C&E

Terminals dwgs

Power consumption

General Arrangement

Foundation drawing and loads, including auxiliaries!

Piping Purchaser Mechanical connection list and dwg

Process

Utility consumption

Battery limit conditions

Engineering / Vendor interfaces

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A unique synthesis for the busy Project professional 270 pages 300 illustrations

Interested and wanting to know more on Engineering?


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The Oil & Gas Engineering Guide 2nd edition

Order direct from the publisher:

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html




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Project


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Procurement

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Inquiry (Call for Tender)

Short listing

Bid analysis

Clarifications

Negotiations

Purchase Order

Expediting

Inspection

Delivery

Warranty Period

Procurement / Steps

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Procurement / Supplier selection criteria

Technical Compliance

Price

Qualification of supplier

Schedule

Load of workshop

References

References with final Client

Financial situation

Annual turn-over

Internal feed-back

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Procurement

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Expediting

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Inspection

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Shipping

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Project


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Earthworks

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Pipeline

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Roads

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Buildings

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Admixtures

Sand

Aggregate

Cement

Civil Works

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Civil Works

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Pre-fabrication

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Erection

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Underground networks

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Plant erection

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Steel structure erection

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Equipment installation

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Piping Pre-fabrication

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Piping erection

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Field Instrumentation Installation

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Electrical equipment connection

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Cable pulling

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Arrangement of Technical rooms

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Cable connections

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Other Systems Field Equipment Installation

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Control room consoles installation

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Testing

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Sub-System

Junction Box

Instrument Loop

Instrument Cable

Mech Equip

Document Folder

Handover System

Elect Equip Circuit

Instrument Tag

Commissioning

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The multiple sides of a Project

Hum

an Resources M

anagement

Project Control

PROJECT

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Project Organisation

Project Manager

Engineering Manager

Project Engineers

Discipline Engineers

Process

Civil

Instrumentation

Electrical

Equipment

Procurement Manager

Purchasers Expediters Inspectors

Site Manager

Construction Manager

Construction Superintendent

Construction supervisor

Construction superintendent

Construction supervisor

Project Control Manager

Contract Manager

Scheduling Manager Cost Control

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Project procedures

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Project temporary facilities

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Construction Procedures

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Quality Control

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Slump

Sampling Temperature

Quality Control

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Quality Control

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Cost Control

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Insurance

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Contracts

P.O.

Sub

P.O.

P.O.

Main Contract

Purchase Orders

Sub-Contracts

EPC

Sub

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Contracts

Main Contract

EPC

Terms and Conditions

Price

Schedule

Performance guarantees

Technical basis

Specifications, codes & stds

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Contracts

E P C

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Contracts

∑ + x%

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Construction contracts

Civil

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Mechanical

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E&I

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General Contractor

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Contracts Terms and Conditions

Main Contract

EPC

Obligations of the 2 parties

Limit of liability

Penalties in case of bad performance

Conflict resolution

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Quality Assurance (QA)

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Discipline code

A Instrumentation & Control

C Civil engineering

E Electrical

G Project general documents

J Mechanical

K Safety

M Piping & Layout

P Processes

S Steel Structures

V Vessels – Heat exchangers

W Materials – Welding

Document code

1 Installation drawings

2 Detail drawings

3 Diagrams

4 Lists – Bill of Quantities

5 Isometrics

6 Calculation notes

7 Specifications

8 Data sheets

9 Requisitions

Document Control

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Document Control

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Document Control

Engineering

Documents submitted to client

Client

Approval/

Comments

Vendors

Documents submission Comments

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Intranet / Internet

Intranet / Internet

Breakdown structures

Projects

Interfaces

Reports

Satellite Engineering

Center

Center 1 Sr. Mgmt Center 2 Sr.

Mgmt

Construction Site

Electronic Document Management System

Engineering documents

Vendor documents

Correspondence etc.

Electronic Document Management System

http://www.shawpipe.com/images/box1.gif

http://images.google.com/imgres?imgurl=web.mit.edu/evolving/img/proj/infrastructure/bigphoto.jpg&imgrefurl=http://web.mit.edu/evolving/projects/infrastructure/&h=274&w=348&prev=/images?q=projects&start=40&svnum=10&hl=en&lr=&ie=UTF-8&o

http://images.google.com/imgres?imgurl=www.enterasys.com/products/items/INTERFACES/INTERFACES.jpg&imgrefurl=http://www.enterasys.com/products/items/INTERFACES/&h=145&w=150&prev=/images?q=interfaces&svnum=10&hl=en&lr=&ie=UTF-8&oe=UTF-8

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Interface Management

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7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36PLANT START-UPPIPING PRE-FABRICATION & INSTALLATION X X X X X X X X X XPIPING MATERIAL & DRAWINGS AT SITEPIPING MATERIAL MANUFACTURING & SHIPPING X X X X X XPURCHASE OF PIPING MATERIALTECHNICAL & COMMERCIAL CLARIFICATIONS X XCALL FOR TENDER FOR PIPING MATERIALPREPARE PIPING MATERIAL TAKE-OFF XPIPING ROUTING STUDIES X X XPIPING & INSTRUMENTATION DIAGRAMS (PIDs)

PROJECT SCHEDULEMONTH

1

1

2 3

3

4 5

2

4 5

5

Scheduling

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Critical path of an Oil & Gas Project


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Progress Monitoring

How would you measure progress?

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Progress Monitoring

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15 years ago: 2D

Today: 3D

Tomorrow: 3D & data

IT

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IT

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Safety

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Safety

Guard Rail System with ToeBoards

Cross Bracing

Planking

Runner

Bearer

Longitudinal Brace

Post

Sill

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Safety

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Human resources / career path

3-5 yrs

5 yrs

Graduate Engineer, 25 years old

5-7 yrs

40-45 yrs old Project Manager

Engineering Manager/ Deputy Project Manager

Project Engineer

Process Engineer

Note: the career pattern shown here is a very fast track one to the PM position... One would enjoy oneself just as well taking more time!


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Do you want to know more... Much more?


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The Oil & Gas Engineering Guide - 2nd edition

Table of Contents


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Table of Contents

Discipline presentation: activities and deliverables


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The work of each

Engineering discipline is described


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Design activities are explained, e.g., Plant

Equipment layout


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Complex activities, such as

QRA, are explained through a practical

example.


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A sample of all common Engineering documents is

included


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Difference between

Engineering and Shop drawings


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Understand the main

technical aspects, e.g., DCS vs ESD


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Table of Contents

The overall process


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Table of Contents


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epc project execution orientation course

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