Epc-Project-Executionpdf - The Execution of A Complex Project Guided Tour

HERVE
BARON The execution of a Complex

Project… a guided tour
© 2015 – Hervé Baron

HERVE
BARON
The actors The suppliers
The
COMPANY
The EPC
“Client”
Contractor
Impossible d’afficher l’image.

The sub-contractors
HERVE
BARON The phases
Sanction Sanction

Conceptual evaluation
Basic Engineering Project Execution
+ Pre-Project
By ENGINEERING by EPC CONTRACTOR
By COMPANY
HERVE
BARON
Design Procurement Manufacturing Shipping
Construction &
Installation Inspection & tests Hand-over
erection

HERVE
BARON The multiple sides of a Project
Project Control
PROJECT
Human Resources Management

HERVE
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The multiple sites of a Project
Engineering Sub-Contractor
Home office (Paris) (India)
•Project management
•Detail Engineering (part) Detail Engineering (part)
•Procurement
Shipyard (Korea)
Hull Engineering & Fabrication
Satellite office
Detail Engineering (part)
Fabrication yard (Nigeria):

Fabrication (part)
Offshore (Nigeria):

Installation, commissioning, start-up
Shipyards (Singapore &
Malaysia)
Topsides Fabrication & Integration
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Project
Engineering Procurement Construction

HERVE
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Project

HERVE The facilities design basis
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Infrastructure:
Process facilities: 50
Administrative and technical
Pressure (bar)
Feedstock and products flow 45 buildings
Feedstock composition 40
Control room
35
Battery limit conditions Access road
30
Equipment Spare 25 Site fencing, gates, check point
20
Performance: 15
Design criteria:
10
Products specifications % 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

Systems:
Process control Applicable codes and standards:
Fire/gas alarm International standards
Public address, LAN, PABX Local rules
HERVE Engineering
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in the Project
Design basis: Documents for Construction:
- Functional Construction drawings &

requirements specifications
Engineering
- Client Documents for Purchase:
specifications
bill of quantity & specification
- Design codes

HERVE
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Project
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping

HERVE
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Project
Instruments& Layout
Control & Piping

HERVE
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Process simulations

HERVE
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Thermodynamic Heat & Material
calculations balance

Process Flow
Diagram (PFD)
HERVE
BARON Equipment list

HERVE
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Equipment
duty

HERVE
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Process data sheet

HERVE
BARON Process Flow Diagram (PFD)

HERVE
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Piping & Instrumentation Diagram (P&ID)

HERVE
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Piping &

Instrumentation
Diagram (P&ID)
HERVE
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Process control

HERVE
BARON Emergency shut down

HERVE
BARON Emergency relief

HERVE
BARON Operating manual

HERVE
BARON
Project
Instruments& Layout
Control & Piping

HERVE
BARON
Rotating machinery

HERVE
BARON Pressure vessels

HERVE
BARON
Heat exchangers

HERVE
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Packages,
Fired Equipment

HERVE
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Process data
sheet
Mechanical
data sheet

HERVE
BARON Material Requisition

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HERVE
HERVE
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Project
Instruments& Layout
Control & Piping

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HERVE
HERVE Fire fighting
BARON

HERVE
BARON Passive fire protection

HERVE
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Fire & Gas detection layout

HERVE Environmental Impact Assessment
BARON

HERVE
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Project
Instruments& Layout
Control & Piping

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HERVE
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HERVE
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HERVE
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HERVE
HERVE
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Equipment supporting
structures
HERVE
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Piping supporting
structures (pipe-racks)
HERVE
BARON Structural design

HERVE
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Structural design

HERVE
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Structural

drawings
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HERVE
HERVE
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Architectural drawings

Equipment layout
drawing
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HERVE
HERVE
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Project
Instruments& Layout
Control & Piping

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HERVE
HERVE
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Layout/
principles

HERVE
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Layout/consideration for all networks

HERVE
BARON General Plot Plan

HERVE
BARON
Piping Layout
drawing

HERVE
BARON 3D modelling

HERVE
BARON
3D model clash check
3D model review

BARON
HERVE
HERVE
BARON
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)

To the above calculated thickness shall be added:
- The corrosion allowance, e.g., 3 mm
- The manufacturing tolerance: 12.5%
HERVE
BARON Thickness (mm) Number of passes

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Isometric drawing

HERVE
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Piping Pre-fabrication

HERVE
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Piping General
Arrangement drawing

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HERVE
HERVE
BARON Standard Pipe Support
drawings

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HERVE
HERVE
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Material Selection

HERVE
BARON Material Specification

HERVE
BARON Material Specification

HERVE
BARON
Project
Instruments& Layout
Control & Piping

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HERVE
HERVE Instrument data sheet
BARON

HERVE
BARON

Process Control System
HERVE System architecture
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drawing

HERVE Mechanical Equipment Control
BARON

HERVE The instrumentation hardware
BARON Instrument room Control room
Marshalling Controller
cabinet cabinet
VDU
PT JB
Process
line CPU
LAN
Secondary cable
Multi cable

HERVE
BARON

Building detail drawing/Telecom and PAGA layout
HERVE Cable routing drawings
BARON

Cable list
HERVE
BARON

Cable routing inside technical rooms
HERVE
BARON
Project
Instruments& Layout
Control & Piping

HERVE
BARON

Electrical consumers list
HERVE
BARON Electrical Load Summary

HERVE
BARON
Electrical distribution

HERVE
BARON
General One
Line Diagram

HERVE
BARON
Generators
Equipment
specification
Switchgear
Transformer

HERVE
BARON Electrical equipment layout

HERVE
BARON
Electrical
Control System

HERVE
BARON
Process design
PFDs
H&M balance

HERVE
BARON
Process design
PFDs
H&M balance
Equipment specification
Process
data sheet
Rotating
Pressure vessels
Fired equipment

Heat exchangers
Packages etc.
HERVE
BARON
Process design
PFDs P&IDs
H&M balance

HERVE
BARON
Process design
PFDs P&IDs
H&M balance
Piping
Instrumentation
Process
data sheet Vendor
Rotating drawings Layout
Pressure vessels
Fired equipment Civil

Heat exchangers
Electrical
Packages etc.
HERVE Engineering work sequence
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Extract from the book: ”The Oil & Gas Engineering
Guide”, Hervé Baron, Editions Technip, 2015, page 209
HERVE Typical 3 year EPC Project Engineering schedule
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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
HERVE
BARON
Process design
PFDs P&IDs
H&M balance
Piping
Instrumentation
Process
data sheet Vendor
Rotating drawings Layout
Pressure vessels
Fired equipment Civil

Heat exchangers
Electrical
Packages etc.
HERVE
BARON
Electrical
Layout Instrumentation &

Vendor Control
Piping
Process
Civil

HERVE Engineering / Vendor interfaces
BARON
Electrical Process
Power consumption Utility consumption

Battery limit conditions
General
Arrangement P&ID
Layout Functional analysis Instrumentation
Vendor & Control
C&E
Piping
Terminals dwgs
Purchaser Mechanical
connection list and
dwg

Foundation drawing and loads,
including auxiliaries!
Civil
HERVE Interested and wanting to know more on Engineering?
BARON
A unique synthesis for

the busy Project
professional
 270 pages
 300 illustrations

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

HERVE
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Project

HERVE
BARON Procurement

HERVE
BARON Procurement / Steps
Inquiry (Call for Tender)

Short listing
Bid analysis
Clarifications
Negotiations
Purchase Order
Expediting
Inspection

Delivery
Warranty Period
HERVE
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
HERVE
BARON Procurement

HERVE
BARON Expediting

HERVE
BARON Expediting

HERVE
BARON Inspection

HERVE
BARON Inspection

Shipping
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HERVE
Shipping
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HERVE
Shipping
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HERVE
HERVE
BARON
Project

HERVE
BARON Earthworks

Pipeline
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HERVE
Pipeline
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HERVE
Roads
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HERVE
Buildings
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HERVE
HERVE
BARON Civil Works
Sand
Aggregate
Cement
Admixtures

HERVE
BARON Civil Works

HERVE
BARON Civil Works

HERVE
BARON Civil Works

HERVE
BARON Civil Works

HERVE
BARON Civil Works

HERVE
BARON Pre-fabrication

Erection
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HERVE
HERVE
BARON Underground networks

HERVE
BARON Plant erection

HERVE
BARON Steel structure erection

HERVE
BARON Equipment installation

HERVE
BARON Equipment installation

HERVE
BARON Piping Pre-fabrication

HERVE
BARON Piping erection

HERVE
BARON Piping erection

HERVE
BARON Field Instrumentation Installation

HERVE
BARON Electrical equipment connection

HERVE
BARON Cable pulling

HERVE
BARON Arrangement of Technical rooms

HERVE
BARON Cable connections

HERVE
BARON Other Systems Field Equipment Installation

HERVE
BARON Control room consoles installation

Testing
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HERVE
HERVE
BARON Commissioning
Handover System
Sub-System
Document Folder
Circuit Elect Equip Mech Equip
Instrument
Loop
Junction Instrument Instrument

Box Cable Tag

HERVE
BARON The multiple sides of a Project
Project Control
PROJECT
Human Resources Management

HERVE
BARON Project Organisation
Project
Manager
Engineering Procurement Project Control

Site Manager
Manager Manager Manager
Project Discipline Construction Contract Scheduling

Purchasers Expediters Inspectors Cost Control
Engineers Engineers Manager Manager Manager
Construction
Process
Superintendent
Construction
Civil
supervisor
Construction
Instrumentation
superintendent
Construction
Electrical
supervisor

Equipment
HERVE
BARON Project procedures

HERVE
BARON Project temporary facilities

HERVE

HERVE

HERVE

HERVE

HERVE
BARON Construction Procedures

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HERVE
HERVE
BARON Quality Control

HERVE
Temperature
Sampling
Slump

HERVE

HERVE
BARON Cost Control

Insurance
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HERVE
HERVE
BARON Contracts
P.O.
P.O.
Purchase
Orders P.O.
EPC
Sub-Contracts
Main Contract Sub

Sub
HERVE
BARON Contracts
Terms and
Conditions
Price
Schedule
Performance
guarantees
EPC
Technical
Main Contract
basis
Specifications,
codes & stds

HERVE
BARON Contracts
E P C

HERVE
BARON Contracts

∑ + x%
HERVE
BARON Construction contracts
Civil

HERVE
Mechanical

HERVE
E&I

HERVE
General
Contractor

HERVE Contracts
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Terms and Conditions
EPC
Main Contract
Obligations of the 2 parties

Limit of liability

Penalties in case of bad performance
Conflict resolution
HERVE
BARON Quality Assurance (QA)

HERVE

HERVE

HERVE

HERVE
BARON 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
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
HERVE

HERVE
Client
Documents Approval/
submitted
to client Comments
Engineering
Documents
Comments

submission
Vendors
HERVE
BARON Electronic Document Management System
Center 1 Sr.
Mgmt Center 2 Sr. Correspondence
Intranet / Mgmt
etc.
Internet
Electronic Document
Management System
Breakdown Projects
structures
Engineering
Reports
documents
Interfaces

Intranet /
Internet
Vendor
Satellite
documents
Engineering Construction
Center Site
HERVE
BARON Interface Management

HERVE
BARON Scheduling
MONTH
PROJECT SCHEDULE
PLANT START-UP
5
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
PIPING PRE-FABRICATION & INSTALLATION

PIPING MATERIAL & DRAWINGS AT SITE 4 X X X X X X X X X X
PIPING MATERIAL MANUFACTURING & SHIPPING X X X X X X

PURCHASE OF PIPING MATERIAL
2 3
TECHNICAL & COMMERCIAL CLARIFICATIONS X X
CALL FOR TENDER FOR PIPING MATERIAL
PREPARE PIPING MATERIAL TAKE-OFF X
PIPING ROUTING STUDIES 1 X X X
PIPING & INSTRUMENTATION DIAGRAMS (PIDs)
1 3 5
4 5
2

HERVE
BARON Critical path of an Oil & Gas Project

Extract from the book: ”The Oil & Gas Engineering Guide”, Hervé Baron, Editions Technip, 2015, page 225
HERVE
BARON Progress Monitoring
How would you measure

progress?

HERVE

HERVE

HERVE

HERVE
BARON IT
Today: 3D
Tomorrow:
15 years ago: 2D
3D & data

IT
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HERVE
Safety
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Safety
Guard Rail System with Toe Planking

Boards
Runner
Bearer
Cross Bracing Post

Sill Longitudinal Brace
Safety
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HERVE
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Human resources / career path
Graduate Engineer, 25 years old
Process Engineer 3-5 yrs
Project Engineer 5 yrs
Engineering Manager/ 5-7 yrs

Deputy Project Manager
Project Manager
40-45 yrs old

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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2nd edition
Do you want to know more... Much more?

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

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Table of Contents
Discipline
presentation:
activities and
deliverables

HERVE
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The work of each

Engineering discipline is
described

HERVE
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Design activities are

explained, e.g., Plant
Equipment layout

HERVE
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Complex activities, such as

QRA, are explained
through a practical
example.

HERVE
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A sample of all common

Engineering documents is
included

HERVE
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Difference between
Engineering and Shop
drawings

HERVE
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Understand the main

technical aspects, e.g.,
DCS vs ESD

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Table of Contents
The overall process

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Table of Contents

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Table of Contents

BARON
Table of Contents

BARON
2nd edition
Order direct from the publisher:
http://www.editionstechnip.com/en/catal
ogue-detail/1111/oil-gas-engineering-
guide-the.html

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HERVE

BARON The execution of a Complex

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Design Procurement Manufacturing Shipping

© 2015 – Hervé Baron

Human Resources Management

© 2015 – Hervé Baron

Fabrication yard (Nigeria):

© 2015 – Hervé Baron

Engineering Procurement Construction

© 2015 – Hervé Baron

Engineering Procurement Construction

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Design basis: Documents for Construction:

- Functional Construction drawings &

© 2015 – Hervé Baron

Engineering Procurement Construction

© 2015 – Hervé Baron

Engineering Procurement Construction

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Process data sheet

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Engineering Procurement Construction

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Engineering Procurement Construction

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Engineering Procurement Construction

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

Engineering Procurement Construction

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

3D model clash check