EPC_Project_Interdepency and Work Flow (1).pdf

EPC Project Interdependency and Work Flow

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Table Of Contents Topic

Page

Introduction to EPC Project Management

5

EPC Project Management work flow

13

Engineering Document Issuance Purpose

19

Engineering Work Flow

21

Procurement work flow

43

On Shore Project Schedule and Schedule dependency

46

Work Front Concept

48

Advance Work Packaging

52

Sample WBS

65

Piping Engineering as case study

73

Vessel Fabrication Work flow as case study

83

3

4

Don’t be like this…

5

EPC Project Management - Introduction

6

EPC Project Management

EPC stands for Engineering, Procurement, Construction and is a prominent form of contracting agreement in the construction industry. The engineering and construction contractor will carry out the detailed engineering design of the project, procure all the equipment and materials necessary, and then construct to deliver a functioning facility or asset to their clients. Companies that deliver EPC Projects are commonly referred to as EPC Contractors.

The EPC phase of the project is also known as the Execution phase which normally follows what is know as a FEED or Front End Engineering Design phase. The FEED is a basic engineering design used as the basis for the EPC phase. The FEED can be divided into separate packages covering different portions of the project. The FEED packages are used as the basis for bidding on when the client offers the EPC work to the market. Under an EPC contract, the contractor designs the installation, procures the necessary materials and builds the project, either directly or by of the work.

In some cases, the contractor carries the project risk for schedule as well as budget in return for a fixed price, called lump sum LSTK depending on the agreed scope of work.

EPCM stands for Engineering, Procurement, Construction Management. This type of contract is different to an EPC Contract in that the Contractor is not directly involved in the construction but is responsible for administering the Construction Contracts. EPCI stands for Engineering Procurement Construction and Installation which is a common form of contracting arrangement in the Offshore Construction Industry. As opposed to an EPC contract, the offshore facility or vessel that is constructed has to be transported and installed at the project location. EPIC stands for Engineering Procurement Installation Commissioning is typically a Lump Sum Turn Key (LSTK) type Contract integrating the responsibility going from the conception to the final acceptance of one or more elements of a production system. It can be awarded for all, or part, of a field development.

7

EPC Project Organization

8

EPC Project Organization

9

Design

Procurement

Manufacturing/ Fabrication

Installation

Construction & Erection

Inspection & FAT

Shipment

Hand-Over

10

Engineering in the Project

11

Engineering Discipline

12

EPC Project Management - Work Flow

13

Engineering Work Flow

Engineering work flow concept is required to be fully understand for someone who involved in the EPC Planning and Activity Sequencing. This concept is applied when the EPC level 4 schedule is developed. The process of engineering work to produce the required deliverables depends on not only within the functional discipline itself but also among the process, mechanical and piping engineering functions.

Engineering in EPC project is the task of translating a set of functional requirement into a full set of drawings and specifications depicting every detail of a facility,

There are many interdependencies between engineering documents. For instance piping routing drawings are issued after the process diagram Is defined. Most of the documents will usually issued several times, at different stages to for review as well as to incorporate the comments. Typically a document is first issued for Internal Review (IFR) of the other disciplines, then to client for comment (IFC), it will be returned to be incorporated with the client comments and issue for Approval (IFA), then for construction (IFC) and last once everything is confirmed and will Approve for Construction (AFC)

Engineering involves varieties of specialties, which include : • Process •Civil and Structure •Mechanical •Piping •Electrical •Instrumentation •General Engineering •Safety

14

The entire strategy is dependent on Engineering and Procurement providing their deliverables to meet Path of Construction.

Contractor mobilizes based on Engineering forecast of IFC EWPs (Engineering Work Packages).

15

Engineering Work Flow Engineering phase is very much concerned with documentation. Engineering Disciplines

Activity

Process

Civil and Structure

Mechanical

Piping

Electrical

Instrumentation

Diagrams

Geographical Drawing Architecture Drawing

Calculations Equipment or material spec, data sheet & requisition Site work spec

16

From Sequential To Concurrent Execution

Engineering

Procurement

Construction

Engineering Procurement Construction 17

Project Execution

The Past: sequential execution

The Present: concurrent execution

18

EPC Project Management - Engineering Document Issue Purposes

19

Issuing Purpose

FYI IAB ICR IFA IFB IFC IFD IFE IFH IFP IFR IFS IFU IFV RLM RTS SFR SFS AFC

For Your Information Issued For As-Built Issued For Construction Record Issued For Approval Issued For Bid Issued For Construction Issued For Design Issued For Estimate Issued For Hazop Issued For Purchase Issued For Review Issued For Squad Check Issued For Use Issued For Void Red Line Mark-up Return To Supplier Supplier Issued For Review Supplier Issued For Squad Check Approved for Construction 20

EPC Project Management - Engineering Work Flow

21

Engineering Workflow

Source : Herve Baron Oil & Gas Engineering Guide slideshare

22

Engineering Workflow

Source : Herve Baron Oil & Gas Engineering Guide slideshare

23

Engineering Document Review Cycle

Rule of credit Step

Review cycle Increment %

Cumulative %

1

Study and design preparation

5%

5%

2

Issue for review (IFR)

10%

15%

3

Issue for approval (IFA)

20%

35%

4

Issue for construction (IFC)

30%

65%

5

Approved for construction

35%

100%

24

Engineering Document Review Cycle

P&ID REVIEW

IFR

HAZOP

IFA

IFC

Vendor Drawing PIPING MTO & PO 25

Document Control

Client

•Engineering submission cut-off •Maintain internal and external baseline

Documents submitted to client

Approval/ Comments

•Client Review cycle. (IFR,IFA,IFC,AFC) •Client Review duration

Engineering •Vendor information criticality for client doc approval

Documents submission

Comments

•Vendor duration to incorporate the comments •Vendor delivery estimation

Vendor

26

Vendor Data Engineering is the integrator of the Plant equipment, and is highly dependent on vendor data

27

Engineering Work Flow – Process Design

Process Design

PFDs H&M balance

P&IDs

Piping Instrumentation

Process data sheet Equipment specification Vendor drawings

Rotating Pressure vessels

Layout

Heat exchangers

Civil

Fired equipment

Electrical

Packages etc.

28

Piping Engineering Flow

PFD Stress ok ? Process equipment list

Piping isometric drawing IFC

29

1st Model review

3D Model 2nd model review

3D Modeling (General)

3rd model review

30

Plot plan Piping Materials

1st Model review (30%)

P&IDs 1st issue

2nd model review (60%)

E&I main cable routing First equipment vendor dwg

3D Model

IFD P&IDs

IFA Instrument cable routing layout IFA instrument cable trench &tray layout IFA Instrument location IFC Instrument location dwg

IFA pipe GA dwg

IFA Skid Tie-in report

IFA piping plan dwg IFA structural GA

IFA General structural deflection & stress analysis report

IFA tubing routing layout

IFA Structural GA dwg

IFA pipe support dwg

3D Modeling (Skid Project)

IFI pipe ISO

3rd model review (90%) IFC pipe GA dwg IFC piping ISO Final piping MTO

31

Skid 3D Modelling – Interdependency 30% PDMS 30% model review Update PDMS model 30% Issue close out report

60% PDMS

Report review by EPCC contractor

60% model review Update PDMS model 60%

90% PDMS

Issue close out report

90% model review Update PDMS model 90%

Successor for 60% PDMS (issue close out report)

Issue close out 90% report

IFI for piping ISO

Report review by EPC contractor Receive final comment from EPC contractor

IFI [Piping Isometric] IFA cable routing layout

IFA instrumentation location IFA pipe support drawing

Successor for 90% PDMS (issue close out report)

IFA piping GA drawing

EPC contractor review piping GA

IFA piping plan drawing

EPC contractor review piping plan

IFA structural GA drawing

EPC contractor review pipe support EPC contractor review structural GA

32

Skid 3D Modelling – Piping GA as example

30% PDMS 30% model review Update PDMS model 30% Issue close out report

60% PDMS

Report review by EPCC contractor

60% model review Update PDMS model 60%

90% PDMS

Issue close out report

90% model review Update PDMS model 90% Issue close out 90% report

Report review by EPC contractor Receive final comment from EPC contractor

Prepare and Submit IFA Rev.A [Piping GA Drawings] EPC Contractor Review [Piping GA Drawings] Incorporate Comments & Submit IFC Rev.0 [Piping GA Drawings]

33

Engineering Work Flow-Process Engineering Process Flow Scheme

Process Study

Process Data Sheet

Process Engineering

Process Engineering Flow Scheme - IFA

Process Engineering Flow Scheme – IFC (Rev 0)

Process Engineering Flow Scheme – IFC (Rev 1)

Process Engineering Flow Scheme – IFC (Rev 2)

Engineering Work Flow- Process, Piping Engineering Process Flow Scheme

Process Study

Process Engineering Flow Scheme - IFA

Process Data Sheet

Piping Routing

Plot Plan

Specification and Standard

Process Engineering Flow Scheme – IFC (Rev 0)

Piping Requisition

Piping General Arrangement Drawing

1st MTO

Piping flexibility study & loading

Vendor inquiry and clarification report

Process Engineering Flow Scheme – IFC (Rev 2)

Process Engineering Flow Scheme – IFC (Rev 1)

Technical and Cost Bid Analysis

Pipe support drawing

ISO drawing

Tie-in list

2nd MTO

Final MTO

Process Engineering Piping Engineering

PO for piping materials

Vendor Drawing

Fabrication

FAT

Delivery at site

Engineering Work Flow- Process, Piping, Mechanical Engineering Process Flow Scheme

Process Study

Process Engineering Flow Scheme - IFA

Process Data Sheet

Process Engineering Flow Scheme – IFC (Rev 0)

Engineering Data Requisition

PO for piping equipments

Piping Routing

Plot Plan

Specification and Standard

Piping Requisition

Vendor drawing

Piping General Arrangement Drawing

1st MTO

Vendor inquiry and clarification report

Requisition for Equipment

Fabrication

Piping flexibility study & loading

Vendor inquiry and clarification report

Process Engineering Flow Scheme – IFC (Rev 2)

Process Engineering Flow Scheme – IFC (Rev 1)

Technical and Cost Bid Analysis

Technical and Cost Bid Analysis

FAT

Equipment loading data

Delivery at site

Pipe support drawing

ISO drawing

Tie-in list

2nd MTO

Final MTO

Process Engineering Piping Engineering

Mechanical Engineering

PO for piping materials

Vendor Drawing

Fabrication

FAT

Delivery at site

Engineering Work Flow –C&S, Mechanical and Piping

Mechanical Equipment List

Specification & Standard

Design/calculation sheets

Piping design/plan

Piping flexibility and loading data

Structure loading data

Specification & Standard

Equipment Loading Data

Design & calculation sheet

Main pipe rack GA drawing

Foundation drawing

Field work construction requisition

Underground composite drawing

Underground piping information

Requisition

Issue inquiry/clarification

PO issuance

Technical and Cost Bid Analysis

Assembly drawing

Civil Engineering Structure Engineering

Mechanical Engineering

Fabrication/ manufacture

Piping Engineering Delivery at site

37

Engineering Work Flow – Electrical & Instrumentation

38

Engineering Work Flow – Instrumentation •Instrument I/O List

•Instrument Index •Instrument Data sheet •Instrument Hookup Diagram

•Instrument Loop Diagram •Instrument Layout Diagram

•Cause & Effect Diagram •Cable Schedule Diagram •Project Interconnection Diagram 39

Engineering Work Flow – Instrumentation I/O List is a contains list of instrumentation which serve as an input or output of control system. Hence the tag number that physically has a cable which connects to the control system appears on I/O list. Instrument index is a document containing list of instrument devices within a plant. Instrument index shall include tag number of all physical instruments

I/O Count will determines the required capacity of a system

Reference Drawing P&ID, HMB

Instrument Index Reference Document Cause & Effect

40

Engineering Work Flow – Instrumentation Instrument Data Sheet is a document containing specification and information of an instrument device. It specifies general information of instrument such as tag number identification, service description, location (line number/equipment number), P&ID number or drawing number reference, process data (if applicable), calibrated range (if applicable), material, performance details (such as accuracy, linearity – if applicable), hazardous certification (for electrical device), accessories required, etc. The details of information in data sheet may differ among each types of instrument such as transmitter, switch, gauge, control valve Once the data sheet completed, it is attached to requisition which to be sent to vendors. Vendors will offer their quotation with various model and manufacturer among the offers. Having been considered its technical and commercial aspects, the instrument is purchased. Following the purchase order, vendor will submit supporting document and drawing. Based on vendor data, instrument data sheet may be updated to accommodate details to make the data sheet “as-built”.

Reference Drawing P&ID, HMB,

Reference Document Instrument specification, piping specification, calculation, vendor catalogue

Instrument Data Sheet

41

Engineering Work Flow – Instrumentation

Hook-up drawing is a detailed drawing showing mounting and connection of instrument to process lines and corresponding list of required material.

Hook-up drawing also gives information the requirement of bulk material for each installation. It also details its specification (size, type and material) and the quantity.

There are two types of hook-up drawing: 1. Process Hook-Up This hook-up drawing contains typical installations for instrument which connects to the process 1. Pneumatic Hook-Up

Reference Drawing P&ID, Installation Detail Specification, Piping Specification

Hookup Drawing

42

Engineering Work Flow – Instrumentation

Instrument Layout is also known as instrument location plan. This drawing shows the exact position of each instruments with reference to plant layout.

The point indication of instrument position and its mounting stand where instrument to be mounted and process tap location.

Often the tap location and the instrument is separated quite distant. In some project, it is not mandatory to show the process tap location

Reference Drawing P&ID, Piping Plan,piping GA and ISO

Instrument Layout

43

Engineering Work Flow – Instrumentation

Cable Schedule is a document containing list of instrument cables to install, cable type, length, origin, destination and route.

Reference Drawing Instrument Cable Layout, Interconnection block diagram

Cable Schedule Reference Document Instrument Index / I/O List

44

EPC Project Management - Procurement Work Flow

45

Procurement Work Flow

Inquiry issued to bidders

Tender Evaluation and client approval

Purchasing request created

Purchasing order placed

Received Key vendor drawings

Approved key vendor drawings

Fabrication

FAT or Final inspection finished

Ex-work

Delivery at site

General procurement work flow and how rule of credit being assigned to each step.

46

Procurement Work Flow

Progress tracking sheet for procurement work flow

Procurement progress calculation excel sheets areavailable for download in ignite.com 47

Typical On-Shore Project Schedule and Dependencies

48

49

Typical Level 1 –On-Shore Project Schedule

Work front Concept

50

Work Front Engineering progress is commonly measured by assigning a weight, usually the required number of required manhours, to each task/deliverable. Once the task is performed/ the deliverable is issued, the corresponding manhours are earned.

The earned progress divided by the total number of manhours gives the % progress. As each engineering task/deliverable is scheduled at certain dates, it is possible to anticipate the progress that should be earned at a given date. It is the planned progress. At regular period, usually on a monthly basis, the actual progress of each activity/deliverable is measured against the planned progress. An actual progress less than the planned progress might show a lack of resources and a need for increased mobilization to get back on plan, following a (re-)forecast progress curve. Although such progress measure is commonly used, it could be deceiving. It indeed reflects rather well the progress of engineering on its own but not how well is engineering supporting the Project schedule. Let’s consider that engineering must issue 2 material requisitions, an urgent one for a Long Lead Item and another one which is required later on. Engineering will earn progress whatever requisition it issues, even if putting the Project in delay by issuing the non urgent requisition first. One sees that the above measure of progress alone is insufficient. It must be complemented by monitoring that important Milestones are met. These Milestones are first of all, the ones associated with the issue of the Requisition for the equipment. Long lead items have naturally to be purchased early. All equipment and packages also need to be purchased as early as their technical definition allows. Indeed, engineering development is highly dependent on information from vendors. The sooner the purchase orders are placed the sooner the vendor information will be available. Next come the Milestones associated with Bulk Material Procurement to support construction, such as the Piping MTO and the Structural Steel MTO (for an off-shore Project). 51

Work Front Then come the Milestones associated with Construction. These are the IFC Plot Plan, a pre-requisite to start any site work, and the IFC P&IDs, a pre-requisite to the issue of Piping isometrics. The 50% IFC Piping isometric milestone comes next, which typically falls half way through the Project, as ensuing works, such as pre-fab and erection have a rather incompressible duration, due to site constraints (capacity of pre-fab shop, space constraints for erection limiting the progress). Even if engineering deliveries are in sequence, the above engineering progress measure might still be deceiving, as it will only reflect the amount of engineering work completed and not the workfront made available to construction. Let’s consider for instance that two foundations are to be cast. The first one is a very large foundation and the second one a small one. Issuing the drawing of either the large or small foundation will earn engineering the same progress, although it will open quite a different workfront to Construction. One sees the necessity to measure the issued Workfront.

In the case of foundations, for instance, this will be done by monitoring the cumulative quantity of concrete (m3) of all issued IFC foundation drawings. Producing an S curve, such as the one shown in next slide, showing both planned and actually issued quantities will give a true picture of how well engineering is supporting civil works. One will similarly monitor, for an On-Shore project, the cumulative quantity of steel (tons) of issued IFC Structural drawings. The cumulative tons (or dia inch) of IFC issued Piping isometrics will show the available piping workfront. Such progress curves, showing the actual versus planned available workfronts are instrumental to monitor engineering progress, identify shortage and take corrective actions (increase mobilisation). It is not perfect however and can still be deceiving, in case of out-of-sequence issues: engineering may have issued drawings representing significant quantities, but that does not generate construction workfront as such works can not be performed at this time (due to lack of access or pre-requisite for another work to be completed before, for instance). 52

Work Front

Construction work-front planning and forecasting processes allow Materials to gather construction work package requirements and material situation throughout the supply chain with appropriate feedback into the EP process 53

Advanced Work Packaging

54

Work Face Planning

Path of Construction

FIWPs EWP

CWP

500 – 1000mhrs

System turn-over drives Construction Construction drives Engineering & Procurement EWPs(Engineering Work Packages) are Engineering deliverables CWPs (Construction Work Packages)& FIWPs (Field Installation Work Packages) are Construction deliverables

55

Work Face Planning

EWPs (Engineering Work Packages) set the precedence for Construction work.

Using the P&IDs (for item count) and Piping Layout Drawings (for lengths) a preliminary list for piping material requirement generated which known as piping MTO (piping material takeoffs) The GA drawing used for pipe erection while the piping ISO are used for pipe prefabrication.

56

Planned Path in Construction Work

Work commences 9 weeks lag

Engineering Work Package (EWP)

Construction Work Package (CWP)

Engineering’s Bill of Material

Procurement Package (PP)

Purchase Order to supplier

Equipment / Material arrives prior to work commencing

Supplier Equipment / material

57

Planned Path in Construction Work

1

2

Forecasting to meet scheduled IFC

Contractor resource mobilized

Work commences 9 weeks lag

Engineering Work Package (EWP)

Construction Work Package (CWP)

Engineering’s Bill of Material

Procurement Package (PP)

Purchase Order to supplier

Equipment / Material arrives prior to work commencing

Supplier Equipment / material

58

Constrained Path of Construction

2 Lag gets squeezed CWP starts late

Contractor resource mobilized

Work commences

9 weeks lag

Engineering Work Package (EWP)

Procurement Package (PP)

Purchase Order to supplier

Construction Work Package (CWP)

Vendor Data needed to complete EW delivered late or incomplete

Equipment / Material arrives prior to work commencing

Supplier Equipment / material

59

Constrained Path of Construction

2

Contractor resource mobilized

Work commences Engineering Work Package (EWP)

Construction Work Package (CWP) How do we improve this interface?

Procurement Package (PP)

Purchase Order to supplier

Supplier Equipment / material

60

Constrained Path of Construction

Work commences Delay in Engineering will cause lag gets squeezed CWP starts late

Engineering Work Package (EWP)

Construction Work Package (CWP)

Model Review causes late changes

MTO can’t be created

How are these mitigated / eliminated?

No IFC or AFC status for P&IDs

Specification is not complete

Client or EPC take longer time for document review and caused delay

It is important to knows the work sequence in order to plan for Construction Work Package. 61

Engineering Work Package Progress

Ex : Piping Work Package. 1

3D modelling development

2

P&IDs

3

Requisitions

4

Specifications.

5

Pipe Stress analysis

6

Calculations

62

Forecasting Scenario

Ex : Piping Work Package. EWP is forecast to meet scheduled IFC

Contractor plans resource mobilization Next Weekly Forecast - EWP slips one week Contractor tries to mitigate

Next Weekly Forecast - EWP slips another week

Delay in Construction work and recovery needed

Delay in Engineering Work Package approval in return cause delay in construction work. 63

Potential Work Flow and Rule of Credit for Piping

Step

Work Flow

Increment %

Cumulative %

1

EWP ID’d and mapped to CWP

5%

5%

2

Initial scope identified (line numbers)

15%

20%

3

Preliminary equipment data received

5%

25%

4

Initial routing of lines established

20%

45%

5

Initial bulk material (BOM) to supply chain

10%

55%

6

Piping studies rec’d for critical lines:

5%

60%

7

Final vendor data received

10%

70%

8

Final routings completed

5%

75%

9

P&IDs and LDT issued IFC

5%

80%

10

Stress analysis for large bore completed

5%

85%

11

BOM completed

5%

90%

12

EWP c/w all drawings/specs issued IFC

5%

95%

13

EWP accepted by Construction AFC

5%

100%

64

What Makes Forecasting is a Challenge

EWP process has many steps to get to IFC

The rules of credit (if they exist) are either not known or not utilized. EWP development held back by outside influence (e.g., Systems, Vendor Data or Owner Decisions)

Challenges Construction mobilizes resources based on forecast completions of EWP IFC

Engineering forced to release partial EWPs or releases EWPs out of sequence or EWPs with HOLDS

EWP releases continue to slip but construction is now mobilized

65

Engineering Work Package and Construction Work Package

CWP Engineering

Scope of Work IFC drwgs Eng.Specs&Stds Equipment/Materials Vendor info Quality Instructions Regulatory approvals/permits Turnover Documents Schedule (Level 5)

Procurement

Construction

Long Leads RAS dates Material Mgmt Expediting Transportation Special Requirements

HSE/Safety Manpower req. Level 4 Schedule QA/QC Construction Tools/Equip Heavy Lift Plans Scaffold Waste Mgmt Interfaces/Coordination

66

Sample WBS

67

WBS Structure

68

WBS Structure

69

Sample WBS for Electrical Construction

70

Sample Pipeline Construction Project WBS for Refinery/Chemical Plant

71

Sample Pipeline Construction Project WBS for Refinery/Chemical Plant Sample WBS for piping construction project for a refinery or chemical plant may be organized as the following. It is worth to be organized by location wise (i.e. platform and pipe rack, platform and equipment around piping) prior to “Phase” WBS. Timely completion of piping construction is not only depending on timely receiving of engineering drawings and materials from Owner/EPC contractor but timely availability of the infrastructure should also be addressed. Sometime it refers to work front availability.

Developing WBS is mainly depending on the project scope. It should be defined according to the project specific as every project is different, for instance, “Demolishing” WBS may also be added under “Phase” level priority to “Installation” WBS if your project scope involved a considerable amount of piping demolishing scope. “Above Ground” and “Under Ground” WBS can be left in case no underground piping work is included in the project. (1) Level 1: Plant Unit, e.g. Utility Unit, Ethylene Theatre Unit, etc. (2) Level 2: Area within a Unit, for instance, Area ABC, Area XYZ. Area demarcation is marked for a group of process piping on above ground and underground.

(3) Level 3: Height. This is to segregate pipe work on the above ground and underground. (4) Level 4: Location where pipeline is run, for instance, piping on and around pipe rack, equipment and equipment platform. (5) Level 5: Phase, e.g. Fabrication, Installation (field erection, NDT) and pre-commissioning (hydro testing, air flushing, chemical cleaning etc.)

Note : “Common” WBS name refers to common location where interconnecting piping is running between the pipe rack and equipment or equipment platform. Having a clear definition of what is and what is not meant by “Common” is important 72

Sample Fuel Tank WBS

External Floating Roof Tank 0

Foundation work 1.0

Field erection works 2.0

Tank Bottom 2.1

Shell side 2.2

Roof works 2.3

Tank accessories installation 2.4

Fire fighting works 2.5

Bottom plates installation 2.1.1

Shell plates installation 2.2.1

Center deck plate installation 2.3.1

Internal Appurtenances 2.4.1

Foam piping installation 2.5.1

Final coating 2.1.2

Nozzles and man ways installation 2.2.2

Drainage piping 2.3.2

External accessories 2.4.2

Final coating 2.5.2

Final Coating 2.2.3

Final Coating 2.3.3

73

Sample Fuel Tank WBS

74

Piping Discipline ( Piping Fabrication, Tie-in and Commissioning )

75

Piping Tie-in Process Normally, piping tie-in installation scope is involved in revamp project only. The progress tracking system for tie-in work includes Tie-in Tracker Sheet and Progress tracking sheet. Tie-in numbers against the Isometric drawings and work packages are listed in the tracker sheet. The tie-in type (Bolt-up, cut and weld, hot tap, cold tap and threaded are typical tie-in types in process industry), project area or system name and installed dates are also included in the tracker sheet.

To develop Progress Tracking Sheet for overall Isometric drawings, the following work steps and weight factor percentages are utilized. 1. Preparation ( Scaffold erection if required/remove insulation if required) 2. Tie-in work (Bolt up/cut & weld/hot tap/cold tap/threaded) 3. Inspection (Sign QC document, example : flange make up check list)

-20% -70% -10%

The Progress Tracking System for Pipeline Erection Work Developing procedure of progress tracking system for pipeline erection work is the same as piping fabrication work except work steps and weight factor percentages. To do that, replace the following work steps and weight factor percentages with the existing ones and rearrange the formulae. 1. Material at Erection area 2. Piping Laying 3. Preparation(align/tack weld) 4. Full Welding Execution 5. Non Destructive Examination 6. Pipe Support Erection 7. Final Inspection

- 5% -20% -20% - 40% - 5% -15% - 5%

76

Commissioning Test package and Tie-In

Piping Fabrication

Piping Tie-In

System Commisionning

Piping Test Package

77

Piping Tie-in Work Sequence

Weld map drawing preparation

Withdrew material

Welding preparation

Spool assemble and tack weld

Welding

NDT

Surface preparation and coating

Final inspection

Delivery at site

General piping tie-in work flow and how rule of credit being assigned to each step.

78

Piping Hydrotest Work Sequence

Preparation Done

Testing

Reinstated

Clear Punch list

General hydrotest work flow and how rule of credit being assigned to each step.

79

Commissioning Test package and Tie-In

Tie-In List

Test Package for Pre- Commissioning

80

Piping Tie-In

81

Special Pipe Support Drawing

82

Piping Pre-Fab Drawing

83

Piping ISO Drawing

84

Vessel Fabrication

85

Vessel Fabrication Work Flow

Exchanger Vessel Fit Up (PreFabrication)

Exchanger Vessel Weld Out (Assembly)

Tubesheet Fit Up / Weld Out

Testing (NDE, Hydro

Painting

Ex-work

86

Vessel Fabrication Work Flow Shell Side Fabrication · Plate marking /cutting/ beveling and inspection · Shell plate rolling work · Longitudinal steel (LS) fit-up and inspection · LS welding and inspection (NDE) · Circumference steel (CS) fit-up and inspection · CS welding and inspection (NDE)

Inlet and outlet nozzles fabrication · Pipe marking/cutting / beveling and inspection · Fit-up and welding of flanges and pipes · Inspection for nozzles to flange joints (NDE) Nozzle Attachments to Dished Head · Marking of nozzle location on dished head · Cutting/opening/ beveling and inspection · Fit-up and tack weld nozzle to dished head · Inspection for tack welding (if required) · Full weld - nozzle assembly with dished head · Inspection for nozzle to dished head welds (NDE)

Dished head Installation · Fit up and tack weld/Inspection – Dished head to shell · Full circumference welding · Inspection for full welds (NDE)

Inspection (Hydro-testing) · Hydrostatic testing · Draining/drying and final inspection

Blasting and Painting · Blasting/Inspection · Primer/Final coating/Inspection

Nozzles and other accessories to Shell · Marking of nozzles location · Cutting/opening/ beveling and Inspection · Fit-up and tack weld nozzle assembly to shell/inspection · Full weld - nozzle assembly with shell · Inspection for nozzle to shell side welds (NDE) · Fit up and welding for instrument attachments · Fit up and welding for lifting lugs

87

Vessel Fabrication Case Study

88

Vessel Fabrication Process

89

Plate Cutting

90

Plate Rolling

91

Longitudinal Seam Welding

92

Longitudinal Seam Welding

93

Can to Can Fit-up

94

Can to Can Fit-up

95

Can to Can Fit-up

96

Tack Weld

97

Weld Inside Circumference of Can

98

Weld Outside Circumference of Can

99

Weld Outside Circumference of Can

100

NDT

101

The End

103