EPC Project Execution.pdf

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The execution of a Complex Project… a guided tour

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The COMPANY “Client”

The actors

The suppliers

The EPC Contractor Impossible d’afficher l’image.

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The sub-contractors

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The phases

Sanction

Basic Engineering By ENGINEERING

Project Execution by EPC CONTRACTOR

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Conceptual evaluation + Pre-Project By COMPANY

Sanction

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Design

Procurement

Manufacturing

Installation

Construction & erection

Inspection & tests

Shipping

Hand-over

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The multiple sides of a Project

Project Control

PROJECT

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Human Resources Management

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The multiple sites of a Project Home office (Paris) •Project management •Detail Engineering (part) •Procurement

Engineering Sub-Contractor (India) Detail Engineering (part)

Shipyard (Korea) Hull Engineering & Fabrication

Satellite office Detail Engineering (part)

Fabrication yard (Nigeria): Fabrication (part)

Installation, commissioning, start-up

Shipyards (Singapore & Malaysia) Topsides Fabrication & Integration

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Offshore (Nigeria):

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Project

Engineering

Procurement

Construction

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Project

Engineering

Procurement

Construction

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The facilities design basis Infrastructure:

Feedstock and products flow Feedstock composition Battery limit conditions

Pressure (bar)

Process facilities:

50

Administrative and technical buildings

45 40

Control room

35

Access road

30

Equipment Spare

Site fencing, gates, check point

25 20

Performance: Products specifications

15

Design criteria:

10

% of over design

5

Energy efficiency, emissions

0 -85

-80

-75

-70

-65

-60

-55

Environment data:

Utilities:

Min/max temperature

Electric power supply

Rain/snow fall

Other utilities

Wind Geological conditions

Process control

Applicable codes and standards:

Fire/gas alarm

International standards

Public address, LAN, PABX

Local rules

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Systems:

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Engineering in the Project

Design basis:

Documents for Construction:

- Functional requirements

Construction drawings & specifications

- Client specifications

Engineering

Documents for Purchase: bill of quantity & specification

- Design codes © 2015 – Hervé Baron

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Project

Instruments& Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Project

Instruments& Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Process simulations

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Thermodynamic calculations

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Process Flow Diagram (PFD)

Heat & Material balance

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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

Instruments& Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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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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© 2015 – Hervé Baron

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Project

Instruments& Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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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

Instruments& Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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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

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Equipment layout drawing

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© 2015 – Hervé Baron

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Project

Instruments& Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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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 © 2015 – Hervé Baron

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3D modelling

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3D model clash check

3D model review © 2015 – Hervé Baron

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© 2015 – Hervé Baron

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Piping Design

Design code for Process plants: ASME B31.3

P*D t= (2SWE + PY) 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) © 2015 – Hervé Baron

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

Instruments& Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Instrument data sheet

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Process Control System

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System architecture drawing

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Mechanical Equipment Control

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The instrumentation hardware Instrument room Marshalling

Controller

cabinet

cabinet

Control room

VDU

PT

JB

Process line

CPU

LAN Secondary cable Multi cable

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Building detail drawing/Telecom and PAGA layout

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Cable routing drawings

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Cable list

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Cable routing inside technical rooms

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Project

Instruments& Control

Layout & Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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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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Equipment specification

Switchgear

Transformer © 2015 – Hervé Baron

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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

Process data sheet

Equipment specification

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Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

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Process design PFDs

P&IDs

H&M balance

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Process design PFDs

P&IDs

H&M balance

Piping Instrumentation

Process data sheet

Equipment specification Vendor drawings

Layout Civil Electrical

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Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

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Engineering work sequence

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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

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Extract from the book: ”The Oil & Gas Engineering Guide”, Hervé Baron, Editions Technip, 2015, page 211

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Process design PFDs

P&IDs

H&M balance

Piping Instrumentation

Process data sheet

Equipment specification Vendor drawings

Layout Civil Electrical

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Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

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Electrical Layout Piping

Vendor

Instrumentation & Control Process

Civil

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Engineering / Vendor interfaces

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Electrical

Process Utility consumption

Power consumption

Battery limit conditions

General Arrangement

Layout

P&ID

Vendor

Piping

Functional analysis C&E

Instrumentation & Control

Terminals dwgs Purchaser Mechanical connection list and dwg

Civil

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Foundation drawing and loads, including auxiliaries!

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Interested and wanting to know more on Engineering?

A unique synthesis for the busy Project professional  270 pages  300 illustrations

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The Oil & Gas Engineering Guide 2nd edition Order direct from the publisher: http://www.editionstechnip.com/en/catal ogue-detail/1111/oil-gas-engineeringguide-the.html

© 2015 – Hervé Baron

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Project

Engineering

Procurement

Construction

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Procurement

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Procurement / Steps

Inquiry (Call for Tender) Short listing Bid analysis Clarifications Negotiations Purchase Order Expediting Inspection

Warranty Period

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Delivery

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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

Internal feed-back

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Annual turn-over

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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 HERVE BARON

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Shipping HERVE BARON

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Shipping HERVE BARON

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Project

Engineering

Procurement

Construction

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Earthworks

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Pipeline HERVE BARON

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Pipeline HERVE BARON

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Roads HERVE BARON

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Buildings HERVE BARON

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Civil Works

Sand Aggregate

Cement Admixtures © 2015 – Hervé Baron

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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 HERVE BARON

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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 HERVE BARON

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Commissioning Handover System

Sub-System Document Folder

Circuit

Elect Equip

Mech Equip Instrument Loop

Instrument Cable

Instrument Tag

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Junction Box

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The multiple sides of a Project

Project Control

PROJECT

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Human Resources Management

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Project Organisation

Project Manager

Engineering Manager

Project Engineers

Procurement Manager

Discipline Engineers

Process

Civil

Instrumentation

Electrical

Expediters

Inspectors

Construction Manager

Contract Manager

Scheduling Manager

Cost Control

Construction Superintendent

Construction supervisor

Construction superintendent

Construction supervisor © 2015 – Hervé Baron

Equipment

Purchasers

Project Control Manager

Site Manager

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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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Quality Control

Temperature

Sampling Slump © 2015 – Hervé Baron

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Quality Control

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Cost Control

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Insurance HERVE BARON

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Contracts

P.O.

P.O.

Purchase Orders

P.O.

EPC Main Contract

Sub-Contracts

Sub

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Sub

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Contracts Terms and Conditions Price Schedule

EPC Main Contract

Performance guarantees Technical basis Specifications, codes & stds © 2015 – Hervé Baron

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Contracts

E P C © 2015 – Hervé Baron

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Contracts

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∑ + 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 © 2015 – Hervé Baron

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Contracts Terms and Conditions

EPC Main Contract

Obligations of the 2 parties Penalties in case of bad performance Conflict resolution

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Limit of liability

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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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Document Control 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 Discipline code 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

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A

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Document Control

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Document Control Client Documents submitted to client

Approval/ Comments

Engineering

Comments

Vendors

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Documents submission

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Electronic Document Management System

Center 1 Sr. Mgmt

Intranet / Internet

Center 2 Sr. Mgmt

Correspondence etc.

Electronic Document Management System Projects

Breakdown structures

Engineering documents

Reports Interfaces

Satellite Engineering Center

Vendor documents Construction Site

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Intranet / Internet

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Interface Management

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Scheduling

MONTH PROJECT SCHEDULE 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 36 PLANT START-UP PIPING PRE-FABRICATION & INSTALLATION X X X X X X X X X X PIPING MATERIAL & DRAWINGS AT SITE PIPING MATERIAL MANUFACTURING & SHIPPING X X X X X X PURCHASE OF PIPING MATERIAL TECHNICAL & COMMERCIAL CLARIFICATIONS X X CALL FOR TENDER FOR PIPING MATERIAL PREPARE PIPING MATERIAL TAKE-OFF X PIPING ROUTING STUDIES X X X PIPING & INSTRUMENTATION DIAGRAMS (PIDs)

5

4

1

1

2 3

5

3

4

5

2 © 2015 – Hervé Baron

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Critical path of an Oil & Gas Project

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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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IT

Today: 3D 15 years ago: 2D

Tomorrow: 3D & data

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IT HERVE BARON

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Safety HERVE BARON

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Safety

Guard Rail System with Toe Boards

Planking

Runner

Bearer

Post

Cross Bracing

Longitudinal Brace

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Sill

Safety HERVE BARON

© 2015 – Hervé Baron

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Human resources / career path Graduate Engineer, 25 years old

Process Engineer

Project Engineer

Engineering Manager/ Deputy Project Manager

Project Manager

3-5 yrs

5 yrs

5-7 yrs

40-45 yrs old © 2015 – Hervé Baron

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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The Oil & Gas Engineering Guide 2nd edition

Do you want to know more... Much more?

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition 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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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

The overall process © 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide - 2nd edition Table of Contents

© 2015 – Hervé Baron

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The Oil & Gas Engineering Guide 2nd edition Order direct from the publisher: http://www.editionstechnip.com/en/catal ogue-detail/1111/oil-gas-engineeringguide-the.html

© 2015 – Hervé Baron