eng mgt training 2015
TRANSCRIPT
HERVE BARON
© 2014 – Hervé Baron
Engineering Management Training
Welcome to this presentation This is a preview of my
Engineering Management training
3 public sessions will be held in 2015:
May 26-28, Paris, France
September 2-4, Paris, France
October 23-26, Lombok (Bali area), Indonesia
HERVE BARON
© 2014 – Hervé Baron
To get familiar with both BASIC and DETAILED Engineering
To know the work of the various Engineering disciplines and get familiar with all common engineering deliverables
To understand the challenges faced by Engineering
To provide you with practical tips on how to control engineering execution by a sub-contractor
Training objectives & scope
HERVE BARON
© 2014 – Hervé Baron
In each Engineering discipline:
Explain the design basis and criteria
Clarify the technical vocabulary
Provide basic technical knowledge
Explain the discipline activities
Show the disciplines deliverables
Explain the sequence of the work with easy to read flow diagrams
Highlight the interfaces with other disciplines
Perform hand-on exercise, in particular sizing
Confirm knowledge acquisition by a Quiz in the end
Training contents
HERVE BARON
© 2014 – Hervé Baron
Textbook, 270 pages
Your training materials
Exercise book, 60 pages
CD Training slides (~1000 nos) Great for your tablets!
http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html
HERVE BARON
© 2014 – Hervé Baron
A word about my pedagogy…
All matters are explained by means of example. That’s the best way to learn!
I ask first before I present anything
You will be asked to find out by yourselves
The purpose is to make the brain wiring for the future
My pedagogy
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 2
Hands-on – mini EPC Project
Key aspects of Engineering • The Technical baseline: the Contractual requirements • Engineering organization, split of Work and resources • Interfaces between disciplines • BASIC vs DETAIL design • Document control • Engineering Interface with Procurement, Construction, Third Parties • IT • Management of changes
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 3
The main challenge: meeting the Project schedule • FEED • EPC
How to control a Contractor • The plan • Progress measurement • Factors that could Impact progress • Engineering Controls and KPIs • Engineering Quality • Critical Points to watch
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
Project development phases Front-end Loading
FEL-1 Business Planning Phase
Objective: Define the business opportunity
Content: Technical assessment, milestone schedule, estimated cost range
Deliverables: Functional requirements, economic evaluation
By: Company
FEL-2 BASIC Engineering/Conceptual Objective: Confirm feasibility,, select technology, refine cost estimate, identify risks
Content: Evaluate alternates, confirm feasibility, develop process design
Deliverables: +/-30% cost estimate, preliminary schedule, layout, process design
By: Contractor
FEL-3 FEED
Objective: refine cost estimate, prepare EPC phase
Content: Evaluate alternates, confirm feasibility, develop process design
Deliverables: +/-10-20% cost estimate, Design basis for EPC, MR for LLI
By: Contractor
gate gate
HERVE BARON
© 2014 – Hervé Baron
Engineering
Documents for Inquiry: Bill of Materials / specifications
Documents submitted to client
Client
Approval/ Comments
Process Design Package (PDP)
Vendors / Sub-Contractors
Quotations Inquiries
Basic Engineering/FEED
Cost Estimate Department
Engineering basis for EPC call for tender
Client
??? ???
What else is delivered at FEED stage?
HERVE BARON
© 2014 – Hervé Baron
Process design
PFDs
H&M balance
Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.
P&IDs
Piping
Instrumentation
Layout
Civil
Electrical
Process data sheet
Equipment specification
Vendor drawings
The Engineering Work process synoptic
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
List of common Engineering Deliverables
HERVE BARON
© 2014 – Hervé Baron
Specifications
Design criteria for civil, structural and building engineering
Design specification for roads
Design specification for sewage and drainage
Specification for plant outdoor lighting
Telecommunication and information system philosophy
Instrumentation and control system design basis
Fire Protection Design
Safety concept
Design philosophy for cathodic protection
Specification for pipe supports design
Technical specification – structural steel materials and fabrication
Specification for asphalt paving
Specification for hot dip galvanized anchor bolts
Technical specification Low Voltage Motors
Technical specification for Machine Monitoring system
Technical specification for control valves
Technical specification for fire detection devices in buildings
Technical specification for wheeled fire extinguishers
Technical specification for isolating joint
Technical specification for cathodic protection materials
Job specification for supply for piping sliding plates
Technical specification for centrifugal pumps
Technical specification for tail gas incinerator
What difference can you see between the 2 sets of specifications?
HERVE BARON
© 2014 – Hervé Baron
The (Basic) Engineering Design Data
Draw the Table of Contents
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
Engineering disciplines: activities and deliverables
PROCESS • Design basis and criteria • Process Simulations, Process Flow Diagrams, HMB, equipment list • Process description • Equipment sizing • P&IDs • Piping specification and sizing • Instrument process specification • Process and Emergency shutdown • Flare study • Operating manual
HERVE BARON
© 2014 – Hervé Baron
Process design criteria
• Design margins • Design Pressure and Temperature criteria • Equipment sizing criteria • Line sizing criteria • Control valve sizing criteria
HERVE BARON
© 2014 – Hervé Baron
Engineering disciplines: activities and deliverables
PROCESS • Design basis and criteria • Process Simulations, Process Flow Diagrams, HMB, equipment list • Process description • Equipment sizing • P&IDs • Piping specification and sizing • Instrument process specification • Process and Emergency shutdown • Flare study • Operating manual
HERVE BARON
© 2014 – Hervé Baron
Process simulations
Input
- Feed composition and conditions
Simulator settings
- Flow scheme - Thermodynamic model - Equipment performance
Output
- Stream flows and composition
- Equipment duty
HERVE BARON
© 2014 – Hervé Baron
Block Flow Diagrams & Process Flow Diagrams
HERVE BARON
© 2014 – Hervé Baron
The Process Flow Diagram (PFD)
Results from process simulations
Depicts the various Equipment within a Process (or Utility) Unit and their sequence
Shows the process controls
The individual drawing item of the PFD is the Equipment Item
HERVE BARON
© 2014 – Hervé Baron
Process eqiupment sizing Case study: Production separator
Sets the gas cross section
Sets the liquid volume
Vessel size
HERVE BARON
© 2014 – Hervé Baron
Process Data Sheet
Contents of the Process Data Sheet: • Design conditions • Overdesign • Fluid properties • Equipment duty • Skeleton drawing & dimensions • Material (generic type) and corrosion allowance • Specification of internals: demister, distributor, baffle etc. • Nozzles list • Allowable pressure drop, fouling factor, Cp, Cv, enthalpy curve (for HX, heaters) •Available NPSH (for pumps)
HERVE BARON
© 2014 – Hervé Baron
Piping & Instrumentation Diagram (P&ID)
What purpose does a P&ID serve?
At design stage: • Defines the design basis for Piping & Instrumentation disciplines • Serves to show and agree the operating and maintenance features between
Engineer and Owner or between Engineer and Vendor • Serves to show the interface with equipment/package vendors • Perform HAZOP review
During operation: • Reference drawing for operator, work permit, plant modifications etc.
HERVE BARON
© 2014 – Hervé Baron
Important features (1/3) Normal operation • Redundancy for critical instruments / safety switches Shutdown • Check valves Start-up • Pressurization • warm-up / purge lines Maintenance • Equipment isolation & bypass: valves, spectacle/blind • Nitrogen injection, vent • Drains • Control and ON/OFF valves isolation • Instrument isolation
Piping & Instrumentation Diagrams (P&IDs)
HERVE BARON
© 2014 – Hervé Baron
Piping & Instrumentation Diagrams (P&IDs)
Various types of P&IDs • Legend and Symbols • Identification & Numbering • Details and Typicals • Process or Utility P&ID • Distribution P&ID • Interconnection P&ID • Pumps auxiliary P&ID • Package P&ID
P&ID representation
Details
HERVE BARON
© 2014 – Hervé Baron
P&ID work sequence
IFR IFD IFC
P&ID Review HAZOP
Piping MTO & 1st PO
Piping MTO & RFQ
Vendor drawings
Piping MTO & Top-up’s
HERVE BARON
© 2014 – Hervé Baron
IFC IFD IFR Contents
Comments from Piping, I&C disciplines
Comments from all disciplines
Finalized interfaces with eqt/package
Issue Piping ISOs
Collect Client comments
Perform HAZOP Perform PID review
Client comments incorporated HAZOP comments incorporated Diameter of utility lines Diameter of process lines Size, number of PSVs and CVs
Exercised Contract Option(s)
Freeze Control system I/O list Perform Piping MTO for 1st Piping purchase
IFC IFD IFR Purpose
Quiz Which revision of P&IDs has the following purpose/contents?
HERVE BARON
© 2014 – Hervé Baron
Process Engineering / schedule Hands-on exercise
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
Process Data Sheet vs Mechanical Data Sheet
Look at the PDS and MDS in your exercise book. What additional information is contained in the MDS? What does Mechanical design entail?
HERVE BARON
© 2014 – Hervé Baron
Equipment / Mechanical
What is a package ?
What is, for Engineering, the purpose to order as a package ?
What is usually ordered as a package ?
Which is the responsible discipline ?
Which document is produced to specify a package ? By whom ?
What are the key things to consider when specifying a package?
HERVE BARON
© 2014 – Hervé Baron
Instrumentation Specification for packaged units
HERVE BARON
© 2014 – Hervé Baron
Test
Equipment Process discipline Equipment/Mechanical discipline
PDS Duty spec
MDS Particular Specification
General Specification
MR
Pressure Vessel
Rotating equipment
Reactor
Heat Exchanger – Shell & Tube
Heat Exchanger – Other type
Fired heater
Package
Identify the documents issued by Engineering to order each type of equipment…
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
HAZOP hands-on exercise
Fill the table
HERVE BARON
© 2014 – Hervé Baron Quantitative Risk Analysis (QRA)
case study: gas leak in Turbo-compressor building
Release Frequency Immediate ignition
ESD & Fire Fighting
Delayed Ignition
Explosion/ Flash-fire
Consequence Event Frequency (ev/y)
0,998 Jet fire ESD & FF 7,779E-030,070
0,002 Jet fire no ESD & FF 1,520E-05
1,11E-01Release/yr
0,949 Dispersion 9,827E-020,930
0,120 Explosion 1,774E-050,028
0,051 0,880 Flash fire 1,301E-04
0,972 Dispersion 5,133E-03
Yes Frequency (event/year)Jet fire ESD & FF 7,779E-03Jet fire no ESD & FF 1,520E-05Explosion 1,774E-05
No Flash Fire 1,301E-04Dispersion 1,034E-01
B04a/b/c/d 5%
Probability of immediate ignition for 1-50 kg/s release rate is 7% (from statistical data)
Gas detectors are provided inside the building, that activate isolation and depressurization. It is assumed that they operate 95% of the time.
Probability of explosion vs flash fire (12%) depends on mass of gas and degree of confinement
?
What is the frequency of an explosion?
Probability of delayed ignition (2.8%) takes into account equipment explosion protection (Ex)
Step 2: Event tree analysis
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
Civil foundation calculation
Input Loads: dead, operating, test, live, wind, seismic, Soil data: bearing capacity, angle of friction, unit weight, boyancy Safety factors (for sliding and overturning) Dimensions to test
Calculation
• Stability check for sliding and overturning
• Bearing pressure check
Overturning axis
Stabilizing moment
De-stabilizing moment
HERVE BARON
© 2014 – Hervé Baron
Foundation guide drawing
HERVE BARON
© 2014 – Hervé Baron
Pipe-rack design
What is usually the governing load? What is the governing design criteria?
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
Layout/principles
PREVAILING WIND
… … …
…
… …
Define the respective position of the 6 items as per good plant layout practice
1
2
3
5
6
4
HERVE BARON
© 2014 – Hervé Baron
On-shore plant: Equipment spacing recommendations as per GE GAP Guidelines 2.5.2
HERVE BARON
© 2014 – Hervé Baron
Layout principles: typical Unit Layout
HERVE BARON
© 2014 – Hervé Baron
Piping installation
Unit Plot Plan Line diagram
HERVE BARON
© 2014 – Hervé Baron
Piping design iso vs Shop iso
HERVE BARON
© 2014 – Hervé Baron Piping installation work process
Piping line diagram
Plot Plan
Piping studies & layout
Piping 3D modelling
Piping stress analysis
Piping isometric drawing
Stress OK?
Piping isometric drawing IFC ?
For some lines, another check is done. By whom? For which lines?
HERVE BARON
© 2014 – Hervé Baron
Piping material management work process
Piping line diagram
Plot Plan
Piping studies & layout
Piping 3D modelling
1st Piping MTO: for Inquiry
Piping isometric drawing
Stress OK?
Piping isometric drawing IFC
PFD
Process eqt list
IFR P&IDs
2nd Piping MTO, for Order
IFD P&IDs
IFC P&IDs 3rd and next
Piping MTOs
?
?
? ?
?
At which project month shall the steps take place?
HERVE BARON
© 2014 – Hervé Baron
Quiz
Put the following tasks in order
Perform piping Material-Take-Off for first purchase
HAZOP
P&ID review between COMPANY and CONTRACTOR
Issue of IFR P&ID
P&ID IFC issue
Issue of IFD P&ID
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
Process Control System
Case of Package controlled by Central Process Control System
What documents from the package Vendor are needed by the DCS Vendor in this case?
HERVE BARON
© 2014 – Hervé Baron
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines • PROCESS • MECHANICAL • SAFETY & ENVIRONMENT • CIVIL • PLANT LAYOUT & PIPING • INSTRUMENTATION • ELECTRICAL
Training Agenda Day 1
HERVE BARON
© 2014 – Hervé Baron
Electrical consumer list
HERVE BARON
© 2014 – Hervé Baron
Electrical Engineering
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 2
Hands-on – mini EPC Project
HERVE BARON
© 2014 – Hervé Baron
Hands-on – mini EPC Project
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 2
Hands-on – mini EPC Project
Key aspects of Engineering • The Technical baseline: the Contractual requirements • Engineering organization, split of Work and resources • Interfaces between disciplines • BASIC vs DETAIL design • Document control • Engineering Interface with Procurement, Construction, Third Parties • IT • Management of changes
HERVE BARON
© 2014 – Hervé Baron
61
ENDORSEMENT: case study
1. CONTRACTOR identifies, in the course of the design, that the capacity of one utility unit foreseen in the DESIGN PACKAGE is not enough. A unit with increased capacity is required.
2. A document part of the exclusions listed in the Endorsement Certificate specifies that Sea Water used for cooling should be discharged no more with no more than 10°C temperature increase. COMPANY now asks for 3°C. This required CTR to put additional cooling facilities.
Discuss CTR’s entitlement to a CHANGE ORDER in each case?
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 2
Hands-on – mini EPC Project
Key aspects of Engineering • The Technical baseline: the Contractual requirements • Engineering organization, split of Work and resources • Interfaces between disciplines • BASIC vs DETAIL design • Document control • Engineering Interface with Procurement, Construction, Third Parties • IT • Management of changes
HERVE BARON
© 2014 – Hervé Baron
Engineering Split of work
Discipline Paris (%) India (%)
Process/HSE Design
Equipment
Electrical
Instrumentation
Civil
Piping
What is the typical share of manhours done in home office versus low cost center?
HERVE BARON
© 2014 – Hervé Baron Engineering Split of work/Piping
Horizontal split
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 2
Hands-on – mini EPC Project
Key aspects of Engineering • The Technical baseline: the Contractual requirements • Engineering organization, split of Work and resources • Interfaces between disciplines • BASIC vs DETAIL design • Document control • Engineering Interface with Procurement, Construction, Third Parties • IT • Management of changes
HERVE BARON
© 2014 – Hervé Baron The Engineering work sequence
Fill the missing captions
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 2
Hands-on – mini EPC Project
Key aspects of Engineering • The Technical baseline: the Contractual requirements • Engineering organization, split of Work and resources • Interfaces between disciplines • BASIC vs DETAIL design • Document control • Engineering Interface with Procurement, Construction, Third Parties • IT • Management of changes
HERVE BARON
© 2014 – Hervé Baron
BASIC vs DETAIL design
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 2
Hands-on – mini EPC Project
Key aspects of Engineering • The Technical baseline: the Contractual requirements • Engineering organization, split of Work and resources • Interfaces between disciplines • BASIC vs DETAIL design • Document control • Engineering Interface with Procurement, Construction, Third Parties • IT • Management of changes
HERVE BARON
© 2014 – Hervé Baron
Origin of changes
Identify the likely impact of the Engineering reviews on the design
New instruments
SIL review
3D model review
P&ID review
QRA
HAZOP
HAZID
New accesses
New valves
ESD logic
Blast resistance
Design criteria
P&IDs Plot Plan
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 3
The main challenge: meeting the Project schedule • FEED • EPC
How to control a Contractor • The plan • Progress measurement • Factors that could Impact progress • Engineering Controls and KPIs • Engineering Quality • Critical Points to watch
HERVE BARON
© 2014 – Hervé Baron
Key Engineering Milestones for an EPC
• P&ID 1st issue • LLI Material Requisition Issued for Purchase • HAZOP • Control valves, PSVs PO • issue of Plot Plan IFC • issue of IFC P&Ids • 50% ISOs issued
At which time (Project Month) must the following be issued/done to support the Project execution?
HERVE BARON
© 2014 – Hervé Baron
Typical level 1 On-Shore EPC Project Engineering schedule
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 3
The main challenge: meeting the Project schedule • FEED • EPC
How to control a Contractor • The plan • Progress measurement • Factors that could Impact progress • Engineering Controls and KPIs • Engineering Quality • Critical Points to watch
HERVE BARON
© 2014 – Hervé Baron
Safety Engineering
In your opinion, how is Safety performing?
HERVE BARON
© 2014 – Hervé Baron
Training Agenda Day 3
The main challenge: meeting the Project schedule • FEED • EPC
How to control a Contractor • The plan • Progress measurement • Factors that could Impact progress • Engineering Controls and KPIs • Engineering Quality • Critical Points to watch
HERVE BARON
© 2014 – Hervé Baron
Engineering progress KPIs
HERVE BARON
© 2014 – Hervé Baron
EPC Key Engineering Milestones and benchmarks
Key Engineering Milestones for an EPC • P&ID 1st issue • LLI PO • HAZOP • 1st model review • 1st Piping PO • Control valves, PSVs PO • Plot Plan IFC • IFC P&IDs • 50% ISOs • Primary steel MTO • Primary steel drawings IFC
Additional Milestones for Off-Shore jobs
HERVE BARON
© 2014 – Hervé Baron
Engineering Manhours benchmarks
FEED: number of Home Office (H.O.) manhours per equipment item • ??? hours
EPC: number of H.O. manhours per equipment item • ??? hours
EPC: number of H.O. manhours per USD of CAPEX? • ??? hour / mln USD
EPC: number of Procurement (Buyer, Expediter, Inspector, Transit) manhours for one Purchase Order? • ???? manhours
Please guess…
HERVE BARON
© 2014 – Hervé Baron
Engineering Management Training
Your instructor:
Hervé Baron, Project Manager
Professional experience/positions held
• Process Engineer (2 years), Production Engineer (2 years)
• Engineering Manager (4 years) for EPC On-Shore 300mln USD Project
• Field Engineering Manager (4 years) for EPC Off-shore (FPSO) 1bln USD Project
• Project Manager (2 years) for 50mln USD EPC revamping
• Project Manager (1 year) for FEED and Basic Design
• Project Control Manager (1 year) for 100,000 manhours FEED
• Contract Manager (3 years) for 700mln USD and 1bln USD EPC
Training experience
Developer and instructor of IFP Training’s
• Engineering Management Training (10 sessions held),
• Project control training (6 sessions held),
Professional experience/Companies worked with
• TOTAL, for 4 years
• SAIPEM, for 8 years
• TECHNIP, for 6 years
HERVE BARON
© 2014 – Hervé Baron
2015 Training schedule
3 training sessions will be held in 2015: Paris: May 26-28, September 2-4
For details and to enroll please go to: http://www.ifptraining.com/course/engineering-management-5219.html
Lombok (near Bali), Indonesia: Oct 20-23
For details and to enroll please go to: http://rhenindo.com/trainings/barons-oil-and-gas-engineering-management/
Pick the location you like!