EPC Project Execution.pdf

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The execution of a Complex Project a guided tour

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The actors

Impossible dafficher limage.

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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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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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, Herv 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

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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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HERVE BARON

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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Order direct from the publisher:

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

Slide Number 1 The actorsSlide Number 3Slide Number 4 The multiple sides of a Project The multiple sites of a ProjectSlide Number 7Slide Number 8Slide Number 9Slide Number 10Slide Number 11Slide Number 12Slide Number 13Slide Number 14Slide Number 15Slide Number 16Slide Number 17Slide Number 18Slide Number 19Slide Number 20Slide Number 21Slide Number 22Slide Number 23Slide Number 24Slide Number 25Slide Number 26Slide Number 27Slide Number 28Slide Number 29Slide Number 30Slide Number 31Slide Number 32Slide Number 33Slide Number 34Slide Number 35Slide Number 36Slide Number 37Slide Number 38Slide Number 39Slide Number 40Slide Number 41Slide Number 42Slide Number 43Slide Number 44Slide Number 45Slide Number 46Slide Number 47Slide Number 48Slide Number 49Slide Number 50Slide Number 51Slide Number 52Slide Number 53Slide Number 54Slide Number 55Slide Number 56Slide Number 57Slide Number 58Slide Number 59Slide Number 60Slide Number 61Slide Number 62Slide Number 63Slide Number 64Slide Number 65Slide Number 66Slide Number 67Slide Number 68Slide Number 69Slide Number 70Slide Number 71Slide Number 72Slide Number 73Slide Number 74Slide Number 75Slide Number 76Slide Number 77Slide Number 78Slide Number 79Slide Number 80Slide Number 81Slide Number 82Slide Number 83Slide Number 84Slide Number 85Slide Number 86Slide Number 87Slide Number 88Slide Number 89Slide Number 90Slide Number 91Slide Number 92Slide Number 93Slide Number 94Slide Number 95Slide Number 96Slide Number 97Slide Number 98Slide Number 99Slide Number 100Slide Number 101Slide Number 102Slide Number 103The Oil & Gas Engineering Guide2nd editionSlide Number 105ProcurementProcurement / StepsProcurement / Supplier selection criteriaProcurementExpeditingExpeditingInspectionInspectionSlide Number 114Slide Number 115 ShippingSlide Number 117Slide Number 118Slide Number 119Slide Number 120Slide Number 121Slide Number 122Slide Number 123Slide Number 124Slide Number 125Slide Number 126Slide Number 127Slide Number 128Slide Number 129Slide Number 130Slide Number 131Slide Number 132Slide Number 133Slide Number 134Slide Number 135Slide Number 136Slide Number 137Slide Number 138Slide Number 139Slide Number 140Slide Number 141Slide Number 142Slide Number 143Slide Number 144Slide Number 145Slide Number 146Commissioning The multiple sides of a Project Project OrganisationProject proceduresSlide Number 151Slide Number 152Slide Number 153Slide Number 154Slide Number 155Slide Number 156Slide Number 157Slide Number 158Slide Number 159Slide Number 160Cost ControlSlide Number 162ContractsContractsContractsContractsConstruction contractsConstruction contractsConstruction contractsConstruction contractsContractsTerms and ConditionsQuality Assurance (QA)Quality Assurance (QA) Quality Assurance (QA)Quality Assurance (QA)Document ControlDocument ControlDocument Control Electronic Document Management System Interface ManagementSlide Number 181Slide Number 182 Progress Monitoring Progress Monitoring Progress Monitoring Progress Monitoring IT IT Safety Safety Safety Human resources / career pathThe Oil & Gas Engineering Guide2nd editionThe Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide - 2nd editionSlide Number 196Slide Number 197Slide Number 198Slide Number 199Slide Number 200Slide Number 201The Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide2nd edition

EPC Project Execution.pdf

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Transcript of EPC Project Execution.pdf