Download - Epc project execution orientation course
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HERVE BARON
© 2015 – Hervé Baron
The execution of a Complex Project… a guided tour
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HERVE BARON
© 2015 – Hervé Baron
The actors
Impossible d’afficher l’image.
The COMPANY
“Client” The EPC Contractor
The suppliers
The sub-contractors
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HERVE BARON
© 2015 – Hervé Baron
Conceptual evaluation + Pre-Project
By COMPANY
Basic Engineering By ENGINEERING
Project Execution by EPC CONTRACTOR
Sanction Sanction
The phases
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HERVE BARON
© 2015 – Hervé Baron
Design Procurement Manufacturing Shipping
Installation Construction & erection Inspection & tests Hand-over
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HERVE BARON
© 2015 – Hervé Baron
The multiple sides of a Project
Hum
an Resources M
anagement
Project Control
PROJECT
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
Process simulations
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HERVE BARON
© 2015 – Hervé Baron
Heat & Material balance
Thermodynamic calculations
Process Flow Diagram (PFD)
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HERVE BARON
© 2015 – Hervé Baron
Equipment list
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HERVE BARON
© 2015 – Hervé Baron
Equipment duty
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HERVE BARON
© 2015 – Hervé Baron
Process data sheet
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HERVE BARON
© 2015 – Hervé Baron
Process Flow Diagram (PFD)
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HERVE BARON
© 2015 – Hervé Baron
Piping & Instrumentation Diagram (P&ID)
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HERVE BARON
© 2015 – Hervé Baron
Piping & Instrumentation Diagram (P&ID)
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HERVE BARON
© 2015 – Hervé Baron
Process control
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HERVE BARON
© 2015 – Hervé Baron
Emergency shut down
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HERVE BARON
© 2015 – Hervé Baron
Emergency relief
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HERVE BARON
© 2015 – Hervé Baron
Operating manual
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
Rotating machinery
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HERVE BARON
© 2015 – Hervé Baron
Pressure vessels
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HERVE BARON
© 2015 – Hervé Baron
Heat exchangers
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HERVE BARON
© 2015 – Hervé Baron
Packages,
Fired Equipment
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HERVE BARON
© 2015 – Hervé Baron
Process data sheet
Mechanical data sheet
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HERVE BARON
© 2015 – Hervé Baron
Material Requisition
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Fire fighting
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HERVE BARON
© 2015 – Hervé Baron
Passive fire protection
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HERVE BARON
© 2015 – Hervé Baron
Fire & Gas detection layout
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HERVE BARON
© 2015 – Hervé Baron
Environmental Impact Assessment
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Equipment supporting structures
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HERVE BARON
© 2015 – Hervé Baron
Piping supporting structures (pipe-racks)
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HERVE BARON
© 2015 – Hervé Baron
Structural design
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HERVE BARON
© 2015 – Hervé Baron
Structural design
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HERVE BARON
© 2015 – Hervé Baron
Structural drawings
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Architectural drawings
Equipment layout drawing
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Layout/
principles
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HERVE BARON
© 2015 – Hervé Baron
Layout/consideration for all networks
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HERVE BARON
© 2015 – Hervé Baron
General Plot Plan
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HERVE BARON
© 2015 – Hervé Baron
Piping Layout drawing
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HERVE BARON
© 2015 – Hervé Baron
3D modelling
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HERVE BARON
© 2015 – Hervé Baron
3D model review
3D model clash check
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Thickness (mm) Number of passes
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Isometric drawing
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HERVE BARON
© 2015 – Hervé Baron
Piping Pre-fabrication
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HERVE BARON
© 2015 – Hervé Baron
Piping General Arrangement drawing
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Standard Pipe Support drawings
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Material Selection
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HERVE BARON
© 2015 – Hervé Baron
Material Specification
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HERVE BARON
© 2015 – Hervé Baron
Material Specification
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Instrument data sheet
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HERVE BARON
© 2015 – Hervé Baron Process Control System
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HERVE BARON
© 2015 – Hervé Baron
System architecture drawing
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HERVE BARON
© 2015 – Hervé Baron
Mechanical Equipment Control
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Building detail drawing/Telecom and PAGA layout
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HERVE BARON
© 2015 – Hervé Baron
Cable routing drawings
Cable list
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HERVE BARON
© 2015 – Hervé Baron Cable routing inside technical rooms
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering
Instruments& Control
Layout & Piping Process Electrical Equipment Civil Safety
Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
Electrical consumers list
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HERVE BARON
© 2015 – Hervé Baron
Electrical Load Summary
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HERVE BARON
© 2015 – Hervé Baron
Electrical distribution
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HERVE BARON
© 2015 – Hervé Baron
General One Line Diagram
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HERVE BARON
© 2015 – Hervé Baron
Generators
Switchgear
Transformer
Equipment
specification
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HERVE BARON
© 2015 – Hervé Baron
Electrical equipment layout
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HERVE BARON
© 2015 – Hervé Baron
Electrical Control System
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HERVE BARON
© 2015 – Hervé Baron
Process design
PFDs
H&M balance
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HERVE BARON
© 2015 – Hervé Baron
Process design
PFDs
H&M balance
Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.
Process data sheet
Equipment specification
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HERVE BARON
© 2015 – Hervé Baron
Process design
PFDs
H&M balance
P&IDs
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HERVE BARON
© 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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HERVE BARON
© 2015 – Hervé Baron
Engineering work sequence
Extract from the book: ”The Oil & Gas Engineering Guide”, Hervé Baron, Editions Technip, 2015, page 209
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 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
![Page 101: Epc project execution orientation course](https://reader034.vdocuments.us/reader034/viewer/2022052307/55498025b4c90554648b48b3/html5/thumbnails/101.jpg)
HERVE BARON
© 2015 – Hervé Baron
Vendor Instrumentation &
Control
Electrical
Layout
Civil
Piping Process
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
A unique synthesis for the busy Project professional 270 pages 300 illustrations
Interested and wanting to know more on Engineering?
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© 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
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
Procurement
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HERVE BARON
© 2015 – Hervé Baron
Inquiry (Call for Tender)
Short listing
Bid analysis
Clarifications
Negotiations
Purchase Order
Expediting
Inspection
Delivery
Warranty Period
Procurement / Steps
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Procurement
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HERVE BARON
© 2015 – Hervé Baron
Expediting
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HERVE BARON
© 2015 – Hervé Baron
Expediting
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HERVE BARON
© 2015 – Hervé Baron
Inspection
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HERVE BARON
© 2015 – Hervé Baron
Inspection
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HERVE BARON
© 2015 – Hervé Baron
Shipping
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HERVE BARON
© 2015 – Hervé Baron
Shipping
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HERVE BARON
© 2015 – Hervé Baron
Shipping
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HERVE BARON
© 2015 – Hervé Baron
Project
Engineering Procurement Construction
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HERVE BARON
© 2015 – Hervé Baron
Earthworks
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HERVE BARON
© 2015 – Hervé Baron
Pipeline
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HERVE BARON
© 2015 – Hervé Baron
Pipeline
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HERVE BARON
© 2015 – Hervé Baron
Roads
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HERVE BARON
© 2015 – Hervé Baron
Buildings
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HERVE BARON
© 2015 – Hervé Baron
Admixtures
Sand
Aggregate
Cement
Civil Works
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HERVE BARON
© 2015 – Hervé Baron
Civil Works
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HERVE BARON
© 2015 – Hervé Baron
Civil Works
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HERVE BARON
© 2015 – Hervé Baron
Civil Works
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HERVE BARON
© 2015 – Hervé Baron
Civil Works
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HERVE BARON
© 2015 – Hervé Baron
Civil Works
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HERVE BARON
© 2015 – Hervé Baron
Pre-fabrication
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HERVE BARON
© 2015 – Hervé Baron
Erection
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HERVE BARON
© 2015 – Hervé Baron
Underground networks
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HERVE BARON
© 2015 – Hervé Baron
Plant erection
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HERVE BARON
© 2015 – Hervé Baron
Steel structure erection
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HERVE BARON
© 2015 – Hervé Baron
Equipment installation
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HERVE BARON
© 2015 – Hervé Baron
Equipment installation
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HERVE BARON
© 2015 – Hervé Baron
Piping Pre-fabrication
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HERVE BARON
© 2015 – Hervé Baron
Piping erection
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HERVE BARON
© 2015 – Hervé Baron
Piping erection
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HERVE BARON
© 2015 – Hervé Baron
Field Instrumentation Installation
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HERVE BARON
© 2015 – Hervé Baron
Electrical equipment connection
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HERVE BARON
© 2015 – Hervé Baron
Cable pulling
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HERVE BARON
© 2015 – Hervé Baron
Arrangement of Technical rooms
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HERVE BARON
© 2015 – Hervé Baron
Cable connections
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HERVE BARON
© 2015 – Hervé Baron
Other Systems Field Equipment Installation
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HERVE BARON
© 2015 – Hervé Baron
Control room consoles installation
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HERVE BARON
© 2015 – Hervé Baron
Testing
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HERVE BARON
© 2015 – Hervé Baron
Sub-System
Junction Box
Instrument Loop
Instrument Cable
Mech Equip
Document Folder
Handover System
Elect Equip Circuit
Instrument Tag
Commissioning
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HERVE BARON
© 2015 – Hervé Baron
The multiple sides of a Project
Hum
an Resources M
anagement
Project Control
PROJECT
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Project procedures
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HERVE BARON
© 2015 – Hervé Baron
Project temporary facilities
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HERVE BARON
© 2015 – Hervé Baron
Project temporary facilities
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HERVE BARON
© 2015 – Hervé Baron
Project temporary facilities
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HERVE BARON
© 2015 – Hervé Baron
Project temporary facilities
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HERVE BARON
© 2015 – Hervé Baron
Project temporary facilities
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HERVE BARON
© 2015 – Hervé Baron
Construction Procedures
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HERVE BARON
© 2015 – Hervé Baron
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HERVE BARON
© 2015 – Hervé Baron
Quality Control
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HERVE BARON
© 2015 – Hervé Baron
Slump
Sampling Temperature
Quality Control
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HERVE BARON
© 2015 – Hervé Baron
Quality Control
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HERVE BARON
© 2015 – Hervé Baron
Cost Control
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HERVE BARON
© 2015 – Hervé Baron
Insurance
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HERVE BARON
© 2015 – Hervé Baron
Contracts
P.O.
Sub
P.O.
P.O.
Main Contract
Purchase Orders
Sub-Contracts
EPC
Sub
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HERVE BARON
© 2015 – Hervé Baron
Contracts
Main Contract
EPC
Terms and Conditions
Price
Schedule
Performance guarantees
Technical basis
Specifications, codes & stds
![Page 165: Epc project execution orientation course](https://reader034.vdocuments.us/reader034/viewer/2022052307/55498025b4c90554648b48b3/html5/thumbnails/165.jpg)
HERVE BARON
© 2015 – Hervé Baron
Contracts
E P C
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HERVE BARON
© 2015 – Hervé Baron
Contracts
∑ + x%
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HERVE BARON
© 2015 – Hervé Baron
Construction contracts
Civil
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HERVE BARON
© 2015 – Hervé Baron
Construction contracts
Mechanical
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HERVE BARON
© 2015 – Hervé Baron
Construction contracts
E&I
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HERVE BARON
© 2015 – Hervé Baron
Construction contracts
General Contractor
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Quality Assurance (QA)
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HERVE BARON
© 2015 – Hervé Baron
Quality Assurance (QA)
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HERVE BARON
© 2015 – Hervé Baron
Quality Assurance (QA)
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HERVE BARON
© 2015 – Hervé Baron
Quality Assurance (QA)
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Document Control
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HERVE BARON
© 2015 – Hervé Baron
Document Control
Engineering
Documents submitted to client
Client
Approval/
Comments
Vendors
Documents submission Comments
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HERVE BARON
© 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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HERVE BARON
© 2015 – Hervé Baron
Interface Management
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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
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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HERVE BARON
© 2015 – Hervé Baron
Progress Monitoring
How would you measure progress?
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HERVE BARON
© 2015 – Hervé Baron
Progress Monitoring
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HERVE BARON
© 2015 – Hervé Baron
Progress Monitoring
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HERVE BARON
© 2015 – Hervé Baron
Progress Monitoring
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HERVE BARON
© 2015 – Hervé Baron
15 years ago: 2D
Today: 3D
Tomorrow: 3D & data
IT
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HERVE BARON
© 2015 – Hervé Baron
IT
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HERVE BARON
© 2015 – Hervé Baron
Safety
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HERVE BARON
© 2015 – Hervé Baron
Safety
Guard Rail System with ToeBoards
Cross Bracing
Planking
Runner
Bearer
Longitudinal Brace
Post
Sill
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HERVE BARON
© 2015 – Hervé Baron
Safety
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HERVE BARON
© 2015 – Hervé Baron
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!
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© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide 2nd edition
Do you want to know more... Much more?
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© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
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© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
Discipline presentation: activities and deliverables
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© 2015 – Hervé Baron
HERVE BARON
The work of each
Engineering discipline is described
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© 2015 – Hervé Baron
HERVE BARON
Design activities are explained, e.g., Plant
Equipment layout
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© 2015 – Hervé Baron
HERVE BARON
Complex activities, such as
QRA, are explained through a practical
example.
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© 2015 – Hervé Baron
HERVE BARON
A sample of all common Engineering documents is
included
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© 2015 – Hervé Baron
HERVE BARON
Difference between
Engineering and Shop drawings
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© 2015 – Hervé Baron
HERVE BARON
Understand the main
technical aspects, e.g., DCS vs ESD
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© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
The overall process
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© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
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© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
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© 2015 – Hervé Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
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© 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