Site Assignment From 05-May-2012 to 08-May-2013

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Barzan Onshore EPC Project

Muhammad Ahmed RanaPiping Design Engineer

Descon Integrated Projects Pvt. Ltd.

Presentation Outlines

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1. Barzan Project Overview2. Spoolgen Operations3. CMS and Spoolgen Interface4. YS/FS Change Sheets5. Site Drawing’s Revision Work6. Field Engineering Support7. Project Pictures

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1. BARZAN PROJECT OVERVIEW

1. Barzan Project Overview

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Total No. of Lines: 50,300 Total Project Dia Inches: 3,600,000 Total No. of Equipments: 1,100

DESCON Scope No. of Lines: 10,600 Total Dia Inches 690,000

Construction Subctractors

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CCC NSH

DESCON QCON

JGC

Subcontractors Scope

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Main Process Trains• A100, Train 1• A200, Train 2

Common Process and Main Utilities • B100• C100

Common Process and Offsite Utilities• B200• C200 & C300

Overall Plot Plan

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Descon Scope Areas

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Sour Water Area MEG Regeneration Condensate Stabilization (Compressor Area) Flare K.O Effluent Treatment Inlet Facilities Area (Slug Catcher) Cooling Tower Area Flare Main Sea Water Line (42”-FRP) 86” Cooling Water Line

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2. SPOOLGEN OPERATIONS

Organogram of Spoolgen and My Responsibilities

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DESCON Planning&

FEDC

About Spoolgen

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Intergraph Software for Automatic Spooling and Joint Marking

Input File is IDF File generated from PDS or PCF File generated from SP3D Software

The outputs CAD Files (Spool drawings for Fabrication) Weld/Joint Information Material data for accurate material allocation Site Assembly/Bolting Information

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Advantages

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Planning and BOQ

Reduces Manhour

Better Material

Allocation and Control

Spool Drawing Preparation and Issuance

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Piping Isometric Review and Joint Marking Preparation of Input Data for Spoolgen Software Spoolgen Operations (FW Marking, Sheet Split) Output files Generation (CAD and Text data) CAD Drawing Along with Data issued to Subcon Maintaining Index and Issuance Control Sheets

Check list and Spoolgen Output

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Check List Used by JGC Joint Number Legends Sample Spool Drawing Sample Weld Info File Sample Material File Sample Assembly File

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3. CMS AND SPOOLGEN INTERFACE

Construction Management System

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JGC In-house software for complete Construction Management

CMS

MateralControl

Test Pack Control

FS Control System

Welding Control

ContructionPlanning

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3D (PDS etc.)

MACS

REQ

PCOM

ETRS / MTCS

SPOOLGEN

CMS

REQ

PO

Spool Piece wise Material Data (LOM)

Weld Joint Data

Assembly Data

PO/Shipping Data

(MSR Data)

E（3D） C（CMS）

Spool Piece Dwg

Spool Dwg

P（PMS）

ISO wise Material Data(LOM)

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4. YS/FS CHANGE SHEETS

YS/FS CHANGE SHEETS

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Change Sheets Preparation for all Isometrics (Engineering) Revisions

Automatically generated from CMS Input for YS is “*.b” files Input for FS is Manually/Site Mark-up All spool drawings are updated as per the isometric

revisions Joint Additions, deletions, and cut and re-welds YS Revision Check List Sample YS sheet YS/FS Tracking Sheet Finally to DHT for Issuance to Subcon.

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5. Site Spool Drawings Revisions Work

Site Revisions Work

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All Changes due to site work other than Engineering Change

Joint Change Request Form (JCRF) Shop Fabrication Errors Site Installation Errors Joint Category Change Change due to Construction Sequence (Hydrotesting) Cut and Re-weld due to RT Failure Joint added due to Random Pipe Length Change due to seam Weld orientation

Sample Site Revision Drawings

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Sample 1, Hydro Testing Sample 2, Change Due To Random Pipe Length

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6. Field Engineering Support

Plate Thickness for Hydrotesting

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Blind for Hydrotesting of 36” Line Mating Flange = 36” 600# ASME B16.47 Ser. B Material A36 Design Pressure = 126.3 barg

Blind Thickness as per ASME Sec VIII Comes out to be 145MM

PAD Overlapping with Seam

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For 52” &56” lines, R.L received 9M instead of plan 11M

Drawings need to be revised as there were additional joints

Calculation of Neck of PAD

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Double PAD for AIV Lines

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FTR (Field Trouble Record) Issuance

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FTR was issued by Subcon to JGC for any kind of problem related to Fabrication/installation of Piping

Sample FTR

Field Trouble Isometrics-1

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Field Trouble Isometrics-2

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Field Trouble Isometrics-3

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Field Trouble Isometrics-4

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Spool dwg Hold and Release

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Spool Fabrication, Installation, Material Issuance, and every thing got hold for YS Drawings

So if there are many such drawings Shop cannot proceed Fabrication

Welders/Fabricators can sit idle in severe conditions if there are too many revisions viz. not acceptable in any case.

Since all changes are not related to shop fabrication, so shop can proceed fabrication for such cases

So, we provided information of spools that shop can proceed fabrication without any impact by revision

Spool dwg Hold and Release

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Spool Drawing With Impact on Fabrication Spool Drawing With No Impact on Fabrication

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7. Project Pictures (FOLDER)

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Thank you for Participation