epc project execution orientation course
DESCRIPTION
An overall presentation showing, by means of illustrations, all sides of an EPC Project. Enjoy!TRANSCRIPT
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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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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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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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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
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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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
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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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
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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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 design
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Structural drawings
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Architectural drawings
Equipment layout drawing
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Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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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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Material Specification
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Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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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
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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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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© 2015 – 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
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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
Extract from the book: ”The Oil & Gas Engineering Guide”, Hervé Baron, Editions Technip, 2015, page 211
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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
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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?
© 2015 – Hervé Baron
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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
Engineering Procurement Construction
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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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Expediting
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Inspection
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Inspection
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Shipping
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Shipping
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Shipping
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Project
Engineering Procurement Construction
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Earthworks
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Pipeline
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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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Civil Works
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Civil Works
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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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Equipment installation
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Piping Pre-fabrication
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Piping erection
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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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Project temporary facilities
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Project temporary facilities
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Project temporary facilities
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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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Construction contracts
Mechanical
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Construction contracts
E&I
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Construction contracts
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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Quality Assurance (QA)
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Quality Assurance (QA)
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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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© 2015 – Hervé Baron
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
Extract from the book: ”The Oil & Gas Engineering Guide”, Hervé Baron, Editions Technip, 2015, page 225
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Progress Monitoring
How would you measure progress?
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Progress Monitoring
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Progress Monitoring
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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!
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide 2nd edition
Do you want to know more... Much more?
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
Discipline presentation: activities and deliverables
© 2015 – Hervé Baron
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The work of each
Engineering discipline is described
© 2015 – Hervé Baron
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Design activities are explained, e.g., Plant
Equipment layout
© 2015 – Hervé Baron
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Complex activities, such as
QRA, are explained through a practical
example.
© 2015 – Hervé Baron
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A sample of all common Engineering documents is
included
© 2015 – Hervé Baron
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Difference between
Engineering and Shop drawings
© 2015 – Hervé Baron
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Understand the main
technical aspects, e.g., DCS vs ESD
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
The overall process
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
© 2015 – Hervé Baron
HERVE BARON
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