oil & gas plant construction, project execution plan

Oil & Gas Plant Construction

Project Execution Plan

Details of how a Gas & Oil Plant is constructed, and how the progress, safety and quality is monitored and controlled. Also the measures to ensure that the site is environmentally friendly.

http://www.slideshare.net/DavidHMoloney/oil-gas-plant-construction-project-execution-planhttps://www.youtube.com/watch?v=PiRY0ERoXfI

6avid H Moloney

4th August 2016

Brief Description

The purpose of this presentation is to give an understanding of the Methods, Plant and Sequence to construct a Gas & Oil Plant .

This presentation can be used to engage Stakeholders and to get the Site Teams commitment to the programme. Also can be used for Induction Training and as a way to capture and share knowledge.

Project Execution Plan (PEP) details how a project will be executed, monitored and controlled.

High in Educational Value and easily understood. Recommended for Continuing Professional Development (CPD)

This Video Presentation is innovative and has many beneficial uses.

http://www.slideshare.net/DavidHMoloney/oil-gas-plant-construction-project-execution-plan

Table of Contents

Contents

Gas Processing Facility

Earthworks includes Excavation, Trenches, Haulage, Grading Backfilling, Filling & Compaction

Earthworks

Excavate & Load Tipper Trucks

Trench Excavation with Stepped Faces

Trench Excavation with Battered Faces

Tipper Trucks Unloading

Spreading & Compaction Clay fillE

art

hw

ork

s

Backfill TrenchE

art

hw

ork

s

Dozer Pushing ClayE

art

hw

ork

s

Dozer Ripping GroundE

art

hw

ork

s

Excavator with Hydraulic RockbreakerE

art

hw

ork

s

Excavate & Load, Cart, Tip & Return

Brief Description

Cycle Time for 7km haulage distance using an Excavator 45 tonne weight and Dumper with a 40 tonne capacity, the cycle time is 34 minutes

Eart

hw

ork

s

7 minutes

14 minutes

3 minutes

14 minutes 7 km

7 km

CABC ( Crushed aggregate base course )E

art

hw

ork

s

Mixing Plant

Testing Compaction

Site Trial

Mixing CABCE

art

hw

ork

s

Spreading & Compaction CABC ( Crushed aggregate base course )E

art

hw

ork

s

Spreading & Compaction CABC ( Crushed aggregate base course ) E

art

hw

ork

s

Spreading & Compaction CABC ( Crushed aggregate base course )E

art

hw

ork

s

Rock - Excavability

The excavability of rock depends mainly on the rock strength and the layer thickness. This diagram shows excavation methods for rock of various strengths and thicknesses, with a free face.

ⓒ David H Moloney

Contents

Insitu Piling Construction - Plant & Methods

3D image to show Plant.

For construction details see my YouTube Channel

Plant & Equipment

Crawler CranePiling HammerCasing Piling RigConcrete PumpConcrete Mixer TrucksTremie PipeReinforcement Cage

Piling Construction - Plant, Methods & SequenceP

iling

Piling Construction - Plant & MethodsP

iling

Pile Load Test

ⓒ David H Moloney

Pili

ng

Sheet Pile Shaft Temporary to Support Excavation

Drive Sheet Piles Excavate & install bracing

Construct Concrete Structure Backfill, remove bracing & sheet piles

ⓒ David H Moloney

Sheet pile Temporary Shaft

ⓒ David H Moloney

Genera

l Item

s

3D Animation to show Sequence

Secant Pile Construction - Sequence, Plant & Methods

3D image to show Sequence, Method & Plant.


ⓒ David H Moloney

Diaphragm Wall Construction - Sequence, Plant & Methods



ⓒ David H Moloney

Contents

Jetty for Oil Tankers

ⓒ David H Moloney

Marin

e

Quay Wall

ⓒ David H Moloney

Marin

e

Breakwater

ⓒ David H Moloney

Marin

e

Dredging & Reclamation

ⓒ David H Moloney

Marin

e

Contents

Reinforced Wall Construction Sequence


ⓒ David H Moloney

Reinforced Wall Construction Sequence

ⓒ David H Moloney

Concre

te

Reinforced Structure Construction Sequence

ⓒ David H Moloney

Concre

te

Reinforced Construction Tank Sequence David H Moloney

ⓒ David H Moloney

Oil InterceptorM

iscella

ne

ous

Used to capture oil / fuel from leaks or spillages that are washed down drains every time it rains.

Oil InterceptorC

oncre

te

Excavation for Underground Pump stationE

art

hw

ork

s

Brief Description

Faces of excavation Stepped &

Well-point Dewatering used.

Contents

Main Equipment

Path of Construction 45

Slug CatcherGenerators – Gas Turbine Flares

Liquid Train Gas Train Compressors

The Pipe Racks carries pipes and cables. The pipes contain gas and liquids that are transported to and from the different processes.

Pipe Rack

Piperack Construction Animation

The Pipe Racks carry pipes and cables between the different processes..

Pipe Rack

Pipe Rack - Expansion Loop

49


Hanging Scaffold

Stairway Tower

Pipe Rack – Scaffold Underslung

Pipe Rack under construction

The slug catcher buffers the incoming gas and liquid, from the wellheads, it also separates the gas from the liquid.

Slug Catcher

Slug Catcher Construction Sequence Animation

Separates the Gas from the Oil & WaterAlso to dissipate any pressure surges

Slug Catcher

Storage of Oil & Water

Steel Circular Tanks Construction

Steel Storage Tank

ⓒ David H Moloney

Str

uctu

ral S

teel

Steel Circular Storage Tank – Construction ⓒ David H Moloney

Contents

Piping Spool Fabrication

Piping Spools are pre-fabricated from pipes and pipe fittings in fabrication shops to reduce on site fabrication costs and provide better quality.

Spool Fabrication in Workshop P

ipew

ork

Pipe Spools examples

Spool Fabrication on site P

ipew

ork

Post Weld Heat Treatment

Non Destructive Testing

Cut

Bevel

Fit-up

Weld

NDT

PWHT

Blasting

Painting

Spool Fabrication Steps

Welding Trials

Welding

Fit up Clamp

Spool Fabrication - Pipe Rolling & Cutting Table P

ipew

ork

Spool Fabrication Spool Rolling & Welding P

ipew

ork

W. Soule & Company USA

Spool Fabrication - Automatic Welding with Pipe RollingP

ipew

ork

W. Soule & Company USA

Welding Positioner / TurntableP

ipew

ork

Anyeke.com.my

Contents

Erect Flares / Columns & Vessels

Cranes Heavy Lift Animation

Lift column from the horizontal and

rotate into the vertical


Erect Flares / Columns & Vessels - 3D Simulation

Flares / Columns / Vessels Erection

Path of Construction 74

Demag CC180-1 300 t crawler crane

72m boom & 42m luffing jib

Tandem Lift to tilt flare from horizontal to vertical

Trunnions

Main Lift Crane

Tail Crane

Contents

Electrical Sub Station 3D Model

3D Model – Used to provide a better understanding

Main Substation Horizontal Cross section

Transformer Bays

HVAC RoomHeat, Ventilation, & Air Conditioning

Battery RoomUPS Room

Local Equipment Room

Chillers

Electrical Sub Station

3D Model - Horizontal cross sections moving upwards

Electrical Sub Station

3D Model - Vertical cross sections moving along building

Structural Steel Building Single Storey

3D images to show Construction Sequence.

ⓒ David H Moloney

Step 1 Set-out Grid Lines Step 2 Holding Down Bolts Step 3 Erect 1st Bay

Step 4 Erect 2nd Bay Step 5 Erect following Bays

Steel Building Single Storey

ⓒ David H Moloney

Str

uctu

ral S

teel

Structural Steel Building Multi Storey

ⓒ David H Moloney

Step 1 Set-out Grid Lines Step 2 Holding Down Bolts Step 3 Erect 1st level use core for stability

Step 4 Complete 1st Level Step 5 Erect following Levels Step 6 Plumb & Align Structure

3D images to show Construction Sequence.

Roof Covering

ⓒ David H Moloney

Str

uctu

ral S

teel

Brief Description

Sequence is

Fix bottom sheet

Fix Vapour barrier

Fix Top Hat section and clips

Fit Insulation

Fix top sheet

Roof Covering

ⓒ David H Moloney

Str

uctu

ral S

teel

Contents

Onshore Gas Pipeline Construction Sequence


Construction of Azerbaijan Oil Pipeline 42” by 450km. Overview Construction Sequence

A typical sequence of activities is- surveying and setting out, preparing the land, stringing out the pipes along the route, excavating the trench, welding and laying the pipes, backfilling the trench with the excavated soil, and reinstating the land to its original condition..

Crossing Railway, Roads, Rivers, etc.Pump Station

Oil Pipeline 42”Contents

Overview Surveying & Setting OutClearing & GradingDouble Jointing i.e. welding 2 pipes togetherStringing out PipesBend Pipes for changes in direction sideways and up & downWelding Pipes into a string, Test Weld by X Ray.Anti-corrosion Coat to JointsTrenching i.e. excavate trenchLowering pipe string into trenchBackfilling TrenchReinstatement of Pipeline ROW (Right-of-Way)Reinstatement of River BanksCrossing - Horizontal Directional DrillingCrossing - Thrust BoringCrossing - River Hydrotest & PiggingTie-in i.e. connect to existing pipelineMiscellaneous

Pause Slides to Read

Overview Pipeline Construction Animation

To see animations, view YouTube film.

Cable laying 132KVa Electric

Cable LayingP

ipew

ork

Brief Description

132 kVa Cable laying .

Cable Laying P

ipew

ork

Contents

Horizontal Directional DrillingP

ipew

ork

Brief Description

Horizontal Directional Drilling under a taxiway.

Process

1. A pilot hole id drilled to the designed profile

2. A reamer is pulled back through the hole to enlarge it

3. A pipe string is pulled into the hole.

Horizontal Directional DrillingP

ipew

ork

Crossings – River, Motorway & RailP

ipew

ork

Overview Pipeline Crossings Construction Animation

Micro TunnellingT

unnels

Micro Tunnelling Sequence David H Moloney

ⓒ David H Moloney

Tunnels

Contents

Includes Sequence, Methods & Equipment

Road Construction

Road Construction Sequence Animation

Asphalt Pavement

Includes Sequence, Methods & Equipment

Fencing & Gates

Fencing

ⓒ David H Moloney

Sequence of Construction

Clear Scrub & Grade ground

Fix Corner & Strainer Posts

Fix Intermediate Posts

Fix Line Wire, Chain-link & Razer wire

Concrete ground beam

FencingM

iscella

ne

ous

Contents

Setting out & Surveying

Contents

Emergency Phone Numbers & Response H

ealth,

Safe

ty &

Environm

ent

HSE Monitoring & Reporting - Dashboard Dashboard is a single page, graphical representation of

current HSE Issues and historical trends

Health,

Safe

ty &

Environm

ent

Safety PrecautionsH

ealth,

Safe

ty &

Environm

ent

Safety DocumentsH

ealth,

Safe

ty &

Environm

ent

Safe System of Work.

To provide a safe system of work is a legal requirement. What this means is that before you ask an employee to do a

job. You ensure that he has received training, has the appropriate personal protective equipment, the work area is safe

and he is unlikely to be injured or cause damage by carrying out the assigned task.

Project Management Plan for Health, Safety, Security and Environment. also Known as (HSSE Plan)

The Project HSSE Management Plan details how safety on site will be managed.

Project Procedures for Health, Safety, Security & Environment

Details the safe way to undertake a task

Methods Statements

Are prepared in advance of starting work, to plan a Safe System of Work on site for all activities that carries a risk. The

contents of a Method Statement, typically include:- Scope & Location of the Works, Programme, Roles & Responsibilities

of Staff. Resources, Work Methodologies and Risk Assessment.

Slide 1 of 2

Safety DocumentsH

ealth,

Safe

ty &

Environm

ent

Safety Risk Assessments

Are prepared to identify and evaluate risks, to adopt control measures to reduce or eliminate risks.

COSHH Sheet

The purpose of the Control Of Substances Hazardous to Health sheet is to identify how to prevent or adequately control

workers exposure to hazardous substances.

Permit to Work.

Is a management system used to control high risk activities by ensuring safety measures are in place prior to starting

work.

Types of work for which permits will be required include:

Excavation and the digging of trenches.

Working at height, including on roofs.

Working in confined spaces, for example entering a manhole.

Hot work, which is welding, soldering or cutting steel with angle grinders or by gas torch.

Slide 2 of 2

Safety Training on Site M

iscella

ne

ous

The purpose of safety training is to provide the knowledge necessary to

perform a job safely

Safety Training Matrix M

iscella

ne

ous

The purpose of safety training is to provide the knowledge necessary to

perform a job safely

Emergency Response Drill H

SE

Drills and exercises are used to rehearse anticipated emergency scenarios

Exposed Existing Underground Utilities

ⓒ David H Moloney

Existing Underground Utilities & Overhead Cables - Safety Measures

ⓒ David H Moloney

Health,

Safe

ty &

Environm

ent

Trench - Safety Measures H

ealth,

Safe

ty &

Environm

ent

Site Safety Posters examplesH

ealth,

Safe

ty &

Environm

ent

Personal Protective Equipment (PPE)H

ealth,

Safe

ty &

Environm

ent

Personal protective equipment (PPE) is protective clothing, helmets, goggles, or other garments or equipment designed to protect the wearer from injury or infection

Environmentally Friendly Site Air, Noise, Water & Soil PollutionH

ealth,

Safe

ty &

Environm

ent

Water Pollution PreventionH

ealth,

Safe

ty &

Environm

ent

Segregation of Waste H

ealth,

Safe

ty &

Environm

ent

Segregation of waste for proper disposal and recycling. Less waste goes to landfill and hazardous waste is treated to make it safe.

Colour Code for Skips & Bins

Putting Waste Concrete to use

ⓒ David H Moloney

Health,

Safe

ty &

Environm

ent

Precast bases for signs and hoarding, Precast blocks for walls.

Contents

Staff Directory

Brief Description

List of staff and their

contact details

Daily Work Record

Brief Description

Daily Work Records showing the

allocation of resources, materials and

work activities carried out daily.

Organogram

Brief Description

Shown are the line and

lateral relationships

between the various team

members and their relative

position in the site

organisation.

Filing System

Quotations Comparison Sheet

Staff Responsibility Matrix

Contents

Quality Assurance Dashboard Dashboard is a single page, graphical representation of

current statistics and historical trends

Site LaboratoryG

enera

l item

s

Contents

Progress Monitoring & Reporting - Dashboard

ⓒ David H Moloney

Dashboard is a single page, graphical representation of current progress and historical trends

Programme for Construction

Gantt Charts to plan and schedule projects

Primary Substation-

Chiller Plant

Pump House

IRRIGATION WATER TANKS

Irrigation Pump House-

POTABLE/FIRE WATER TANK

Programme using Timeline & 3D Images

Airport Central Utility Yard

Pump House

Piling

Primary Substation-711

Chiller Plant-714Pump House-715

Irrigation Pump House-716



IRRIGATION WATER TANK




IRRIGATION WATER TANK


POTABLE/FIRE WATER TANK

Time Chainage Diagram The chart has two axis: one for time and the other for location

A legend explains meaning of the colours, symbols and line types

Sample Only

Histogram Charts for Resources & Outputs

Concrete, Manpower, TBM,

Manpower per Discipline Concrete per Location

Numbers for each month of the Project Quantity for each month of the Project

ⓒ David H Moloney

Contents

Temporary Contractors Site Facilities

ⓒ David H Moloney

Brief Description

Site Offices, Camp Accommodation for 1,250 workers, Canteen, Recreation, Fabrication shops, Stores, Plant Yard. In five locations along the route.

Wheel Wash Drive-throughG

enera

l Item

s

Weighbridge & Sheeting Access

ⓒ David H Moloney

Genera

l Item

s

Access tower for covering tipper truck bodies to prevent air pollution.

Dewatering

ⓒ David H Moloney

Genera

l Item

s

Brief Description

Construction dewatering is the removal or

drainage of groundwater and or surface /

rain water usually by pumping to keep the

works dry.

Quarry & Aggregate Production

3D image to show Sequence, Method & Plant. ⓒ David H Moloney

Rock is blasted free from a quarry face and fragmented. The blasted rock is crushed and screened to produce different size ranges of aggregates

Quarry & Aggregate ProductionG

enera

l Item

s

Concrete Batching Plant David H Moloney

ⓒ David H Moloney

Concrete batching plant comprises - concrete mixer, control cabin, silos for cement and fly ash, aggregate bins and conveyor belt system to feed the mixer. Also aggregate storage bays and water storage tanks. The mixing is computer controlled and has a dynamic screen display, showing the process. Material storage capacity to match two days concrete production

Concrete Batching Yard 3 Nr MixersG

enera

l Item

s

Concrete MixG

enera

l Item

s

A concrete mix contains 5 major

elements: cement, water, coarse

aggregates, fine aggregates (sand) and

air in different proportion. Additional

elements such as pozzolanic materials (fly

ash, silica fumes or slag) and chemical

admixtures can also be incorporated to

the mix to increase its properties.

Reinforcement Cutting & Bending Yard David H Moloney

ⓒ David H Moloney

Reinforcement in 12 m lengths. Delivery in 3 ton Bundles Reinforcement cut to length by Shearing Machine

Reinforcement Bent to Shape by Bending Machine Reinforcement that is cut and bent is Bundled for delivery to work site

Contents

Production by David H Moloney

My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

ⓒ David H Moloney

https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

oil & gas plant construction, project execution plan

Engineering