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Engineering Management Training

HERVE
BARON

Welcome to this presentation


This is a preview of my
Engineering Management training

3 public sessions will be held in 2015:


May 26-28, Paris, France

September 2-4, Paris, France

October 23-26, Lombok (Bali area), Indonesia

2014 Herv Baron

HERVE
BARON

Training objectives & scope

To get familiar with both BASIC and DETAILED Engineering


To know the work of the various Engineering disciplines and get
familiar with all common engineering deliverables
To understand the challenges faced by Engineering
To provide you with practical tips on how to control engineering
execution by a sub-contractor

2014 Herv Baron

HERVE
BARON

Training contents

In each Engineering discipline:


Explain the design basis and criteria
Clarify the technical vocabulary
Provide basic technical knowledge
Explain the discipline activities
Show the disciplines deliverables
Explain the sequence of the work with easy to read flow diagrams
Highlight the interfaces with other disciplines

Confirm knowledge acquisition by a Quiz in the end

2014 Herv Baron

Perform hand-on exercise, in particular sizing

HERVE
BARON

Textbook, 270 pages

Your training materials


Exercise book, 60 pages

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html

2014 Herv Baron

CD
Training slides (~1000 nos)
Great for your tablets!

HERVE
BARON

My pedagogy

A word about my pedagogy

All matters are explained by means of example. Thats the best way
to learn!

I ask first before I present anything

You will be asked to find out by yourselves

The purpose is to make the brain wiring for the future


2014 Herv Baron

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

2014 Herv Baron

Training Agenda
Day 2

HERVE
BARON

Hands-on mini EPC Project

Key aspects of Engineering

The Technical baseline: the Contractual requirements


Engineering organization, split of Work and resources
Interfaces between disciplines
BASIC vs DETAIL design
Document control
Engineering Interface with Procurement, Construction, Third Parties
IT

Management of changes
2014 Herv Baron

Training Agenda
Day 3

HERVE
BARON

The main challenge: meeting the Project schedule


FEED
EPC

How to control a Contractor


The plan
Progress measurement
Factors that could Impact progress
Engineering Controls and KPIs
Engineering Quality
Critical Points to watch

2014 Herv Baron

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

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Project development phases


Front-end Loading

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BARON

gate

gate

FEL-2
BASIC Engineering/Conceptual

FEL-3
FEED

Objective: Define the


business opportunity

Objective: Confirm feasibility,,


select technology, refine cost
estimate, identify risks

Objective: refine cost estimate,


prepare EPC phase

Content: Technical
assessment, milestone
schedule, estimated cost
range

Content: Evaluate alternates,


confirm feasibility, develop
process design

Content: Evaluate alternates,


confirm feasibility, develop
process design

Deliverables: Functional
requirements, economic
evaluation

Deliverables: +/-30% cost


estimate, preliminary schedule,
layout, process design

Deliverables: +/-10-20% cost


estimate, Design basis for EPC,
MR for LLI

By: Company

By: Contractor

By: Contractor

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FEL-1
Business Planning Phase

Basic Engineering/FEED

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Client
Documents
submitted to
client

Process Design
Package (PDP)

Approval/
Comments

Engineering

Vendors / SubContractors
Inquiries

Cost Estimate Department


Documents for Inquiry:
Bill of Materials / specifications
Client
Engineering basis for EPC call for
tender
???

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???

What else is delivered at FEED stage?

Quotations

The Engineering Work process synoptic

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BARON

Process design
PFDs

P&IDs

H&M balance

Piping
Instrumentation

Process
data sheet

Equipment specification

Layout
Civil
Electrical

2014 Herv Baron

Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.

Vendor
drawings

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

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HERVE
BARON

List of common Engineering Deliverables

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Specifications

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What difference can you see between the 2 sets of specifications?


Design criteria for civil, structural and building
engineering

Technical specification structural steel materials and


fabrication

Design specification for roads

Specification for asphalt paving

Design specification for sewage and drainage

Specification for hot dip galvanized anchor bolts

Specification for plant outdoor lighting

Technical specification Low Voltage Motors

Telecommunication and information system philosophy

Technical specification for Machine Monitoring system

Instrumentation and control system design basis

Technical specification for control valves

Fire Protection Design

Technical specification for fire detection devices in


buildings

Safety concept
Design philosophy for cathodic protection
Specification for pipe supports design

Technical specification for wheeled fire extinguishers


Technical specification for isolating joint
Technical specification for cathodic protection materials

Technical specification for centrifugal pumps


Technical specification for tail gas incinerator

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Job specification for supply for piping sliding plates

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The (Basic) Engineering Design Data


Draw the
Table of
Contents

2014 Herv Baron

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

2014 Herv Baron

Engineering disciplines: activities and deliverables

HERVE
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PROCESS
Design basis and criteria
Process Simulations, Process Flow Diagrams, HMB, equipment list
Process description
Equipment sizing
P&IDs
Piping specification and sizing
Instrument process specification
Process and Emergency shutdown
Flare study
Operating manual

2014 Herv Baron

HERVE
BARON

Process design criteria

Design margins
Design Pressure and Temperature criteria
Equipment sizing criteria
Line sizing criteria
Control valve sizing criteria

2014 Herv Baron

Engineering disciplines: activities and deliverables

HERVE
BARON

PROCESS
Design basis and criteria
Process Simulations, Process Flow Diagrams, HMB, equipment list
Process description
Equipment sizing
P&IDs
Piping specification and sizing
Instrument process specification
Process and Emergency shutdown
Flare study
Operating manual

2014 Herv Baron

Process simulations

HERVE
BARON

Input
- Feed composition and
conditions

Simulator settings
- Flow scheme
- Thermodynamic model
- Equipment performance

Output
- Stream flows and
composition
- Equipment duty

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HERVE
BARON

Block Flow Diagrams & Process Flow Diagrams

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HERVE
BARON

The Process Flow Diagram (PFD)

Results from process simulations

Depicts the various Equipment within a Process (or Utility) Unit and their sequence

Shows the process controls

The individual drawing item of the PFD is the Equipment Item

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Process eqiupment sizing


Case study: Production separator
Sets the gas
cross section

Vessel size

Sets the liquid volume

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Process Data Sheet

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Contents of the Process Data Sheet:


Design conditions
Overdesign
Fluid properties
Equipment duty
Skeleton drawing & dimensions
Material (generic type) and
corrosion allowance
Specification of internals:
demister, distributor, baffle etc.
Nozzles list
Allowable pressure drop, fouling
factor, Cp, Cv, enthalpy curve (for
HX, heaters)
Available NPSH (for pumps)

HERVE
BARON

Piping & Instrumentation Diagram (P&ID)

What purpose does a


P&ID serve?

During operation:
Reference drawing for operator, work permit, plant modifications etc.

2014 Herv Baron

At design stage:
Defines the design basis for Piping & Instrumentation disciplines
Serves to show and agree the operating and maintenance features between
Engineer and Owner or between Engineer and Vendor
Serves to show the interface with equipment/package vendors
Perform HAZOP review

HERVE
BARON

Piping & Instrumentation Diagrams (P&IDs)

Important features (1/3)

2014 Herv Baron

Normal operation
Redundancy for critical instruments / safety switches
Shutdown
Check valves
Start-up
Pressurization
warm-up / purge lines
Maintenance
Equipment isolation & bypass: valves, spectacle/blind
Nitrogen injection, vent
Drains
Control and ON/OFF valves isolation
Instrument isolation

HERVE
BARON
Various

Piping & Instrumentation Diagrams (P&IDs)


types of P&IDs

Legend and Symbols


Identification & Numbering
Details and Typicals
Process or Utility P&ID
Distribution P&ID
Interconnection P&ID
Pumps auxiliary P&ID
Package P&ID

P&ID
representation

Details

2014 Herv Baron

P&ID work sequence

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BARON

Vendor drawings

P&ID
Review

IFR

HAZOP

IFD
Piping MTO
& 1st PO

Piping MTO
& Top-ups

2014 Herv Baron

Piping MTO
& RFQ

IFC

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BARON

Quiz
Which revision of P&IDs has the following purpose/contents?

Purpose
Collect Client comments
Perform PID review
Perform HAZOP
Perform Piping MTO for 1st Piping purchase
Freeze Control system I/O list
Issue Piping ISOs
Contents
Comments from all disciplines

IFR

IFD

IFC

IFR

IFD

IFC

Comments from Piping, I&C disciplines


Finalized interfaces with eqt/package
Exercised Contract Option(s)
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Size, number of PSVs and CVs


Diameter of process lines
Diameter of utility lines
HAZOP comments incorporated
Client comments incorporated

HERVE
BARON

Process Engineering / schedule


Hands-on exercise

2014 Herv Baron

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

2014 Herv Baron

HERVE
BARON

Process Data Sheet vs Mechanical Data Sheet

2014 Herv Baron

Look at the PDS and MDS in your exercise book. What additional
information is contained in the MDS? What does Mechanical
design entail?

HERVE
BARON

Equipment / Mechanical

What is a package ?
What is, for Engineering, the purpose
to order as a package ?
What is usually ordered as a package ?
Which is the responsible discipline ?
Which document is produced to specify
a package ? By whom ?

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What are the key things to consider


when specifying a package?

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BARON

Instrumentation Specification for packaged units

2014 Herv Baron

Test

HERVE
BARON

Identify the documents issued by Engineering to order each type of


equipment
Equipment

Process discipline Equipment/Mechanical discipline


PDS

Duty
spec

MDS

Particular
General
Specification Specification

MR

Pressure Vessel
Rotating equipment
Reactor
Heat Exchanger Shell &
Tube
Heat Exchanger Other type
Package

2014 Herv Baron

Fired heater

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

2014 Herv Baron

HAZOP
hands-on exercise

HERVE
BARON

Fill the table


2014 Herv Baron

Quantitative Risk Analysis (QRA)


case study: gas leak in Turbo-compressor building

HERVE
BARON

Step 2: Event tree analysis


Release Frequency

Probability of immediate ignition


for 1-50 kg/s release rate is 7%
(from statistical data)

Immediate ESD & Fire


ignition
Fighting

0,998
0,070

Delayed
Ignition

Explosion/
Flash-fire

Consequence Event

Gas detectors are provided inside the building, that


activate isolation and depressurization.
assumed
Jet fire ESD It& is
FF
that they operate 95% of the time.

0,002

Jet fire no ESD & FF

7,779E-03
1,520E-05

Probability of explosion vs flash fire (12%) depends


on mass of gas and degree of confinement

1,11E-01
Release/yr
0,949

Dispersion

9,827E-02

0,120

Explosion

1,774E-05

0,880

Flash fire

1,301E-04

Dispersion

5,133E-03

0,930
0,028
0,051
0,972
Yes

5%

What is the frequency of an explosion?

2014 Herv Baron

Frequency (event/year)
Jet fire ESD & FF
7,779E-03
Probability of delayed ignition (2.8%)Jet
takes
into
account
fire no ESD & FF
1,520E-05
equipment explosion protection (Ex) Explosion
1,774E-05
Flash Fire
1,301E-04
Dispersion
1,034E-01

No
B04a/b/c/d

Frequency (ev/y)

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

2014 Herv Baron

Civil foundation calculation

HERVE
BARON

Overturning
axis
Input
Loads: dead, operating,
test, live, wind, seismic,
Soil data: bearing
capacity, angle of
friction, unit weight,
boyancy

Dimensions to test

Stability check
for sliding and
overturning
Bearing
pressure check

De-stabilizing
moment

Stabilizing
moment

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Safety factors (for


sliding and overturning)

Calculation

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BARON

Foundation guide drawing

2014 Herv Baron

HERVE
BARON

Pipe-rack design

What is usually the governing load?


What is the governing design criteria?

2014 Herv Baron

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

2014 Herv Baron

Layout/principles

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BARON

Define the respective position of the 6


items as per good plant layout practice

PREVAILING WIND

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4
2

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BARON

On-shore plant: Equipment spacing recommendations


as per GE GAP Guidelines 2.5.2

2014 Herv Baron

HERVE
BARON

Layout principles: typical Unit Layout

2014 Herv Baron

Piping installation

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BARON

Line diagram

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Unit Plot Plan

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BARON

Piping design iso vs Shop iso

2014 Herv Baron

Piping installation work process

HERVE
BARON

Plot
Plan

Piping
line
diagram

Piping
studies
& layout

Piping 3D
modelling

Piping
isometric
drawing

Stress
OK?

Piping
isometric
drawing IFC

Piping stress analysis

By whom?
For which lines?

2014 Herv Baron

For some lines, another


check is done.

Piping material management work process

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BARON

PFD
Plot
Plan
Process
eqt list

Piping
line
diagram

Piping
studies &
layout

1st Piping MTO:


for Inquiry

Stress
OK?

Piping
isometric
drawing
IFC

?
IFD
P&IDs

IFC
P&IDs

At which project month shall the steps take place?

3rd and next


Piping MTOs
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Piping
isometric
drawing

2nd Piping MTO,


for Order

?
IFR
P&IDs

Piping 3D
modelling

HERVE
BARON

Quiz

Put the following tasks in order

Perform piping Material-Take-Off for first purchase

HAZOP

P&ID review between COMPANY and CONTRACTOR

Issue of IFR P&ID

P&ID IFC issue

Issue of IFD P&ID


2014 Herv Baron

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

2014 Herv Baron

HERVE
BARON

Process Control System

Case of Package
controlled by Central
Process Control
System

2014 Herv Baron

What documents from


the package Vendor are
needed by the DCS
Vendor in this case?

Training Agenda
Day 1

HERVE
BARON

Engineering in the Project: Role, Organization, Documents,


Generalities

General documents, Design basis and design criteria

The engineering disciplines


PROCESS
MECHANICAL
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
INSTRUMENTATION
ELECTRICAL

2014 Herv Baron

HERVE
BARON

Electrical consumer list

2014 Herv Baron

HERVE
BARON

Electrical Engineering

2014 Herv Baron

HERVE
BARON

Training Agenda
Day 2

Hands-on mini EPC Project

2014 Herv Baron

HERVE
BARON

Hands-on mini EPC Project

2014 Herv Baron

Training Agenda
Day 2

HERVE
BARON

Hands-on mini EPC Project

Key aspects of Engineering

The Technical baseline: the Contractual requirements


Engineering organization, split of Work and resources
Interfaces between disciplines
BASIC vs DETAIL design
Document control
Engineering Interface with Procurement, Construction, Third Parties
IT

Management of changes
2014 Herv Baron

HERVE
BARON

1.

CONTRACTOR identifies, in the course of the design, that the capacity of one
utility unit foreseen in the DESIGN PACKAGE is not enough. A unit with
increased capacity is required.
A document part of the exclusions listed in the Endorsement Certificate
specifies that Sea Water used for cooling should be discharged no more with no
more than 10C temperature increase. COMPANY now asks for 3C. This
required CTR to put additional cooling facilities.

Discuss CTRs entitlement to a CHANGE ORDER in each case?

2014 Herv Baron

2.

ENDORSEMENT: case study

61

Training Agenda
Day 2

HERVE
BARON

Hands-on mini EPC Project

Key aspects of Engineering

The Technical baseline: the Contractual requirements


Engineering organization, split of Work and resources
Interfaces between disciplines
BASIC vs DETAIL design
Document control
Engineering Interface with Procurement, Construction, Third Parties
IT

Management of changes
2014 Herv Baron

Engineering Split of work

HERVE
BARON

What is the typical


share of manhours
done in home office
versus low cost
center?

Discipline

Paris (%)

India (%)

Process/HSE Design
Equipment
Electrical
Civil
Piping

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Instrumentation

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BARON

Engineering Split of work/Piping


Horizontal split

2014 Herv Baron

Training Agenda
Day 2

HERVE
BARON

Hands-on mini EPC Project

Key aspects of Engineering

The Technical baseline: the Contractual requirements


Engineering organization, split of Work and resources
Interfaces between disciplines
BASIC vs DETAIL design
Document control
Engineering Interface with Procurement, Construction, Third Parties
IT

Management of changes
2014 Herv Baron

HERVE
BARON

The Engineering work sequence


Fill the missing captions

2014 Herv Baron

Training Agenda
Day 2

HERVE
BARON

Hands-on mini EPC Project

Key aspects of Engineering

The Technical baseline: the Contractual requirements


Engineering organization, split of Work and resources
Interfaces between disciplines
BASIC vs DETAIL design
Document control
Engineering Interface with Procurement, Construction, Third Parties
IT

Management of changes
2014 Herv Baron

HERVE
BARON

BASIC vs DETAIL design

2014 Herv Baron

Training Agenda
Day 2

HERVE
BARON

Hands-on mini EPC Project

Key aspects of Engineering

The Technical baseline: the Contractual requirements


Engineering organization, split of Work and resources
Interfaces between disciplines
BASIC vs DETAIL design
Document control
Engineering Interface with Procurement, Construction, Third Parties
IT
Management of changes
2014 Herv Baron

Origin of changes

HERVE
BARON

Identify the likely impact of the Engineering reviews on the design


Plot
Plan

P&IDs Design Blast


ESD
criteria resistance logic

New
New
New
valves instruments accesses

HAZID
HAZOP
QRA

2014 Herv Baron

P&ID
review
3D
model
review
SIL
review

Training Agenda
Day 3

HERVE
BARON

The main challenge: meeting the Project schedule


FEED
EPC

How to control a Contractor


The plan
Progress measurement
Factors that could Impact progress
Engineering Controls and KPIs
Engineering Quality
Critical Points to watch

2014 Herv Baron

Key Engineering Milestones for an EPC

HERVE
BARON

At which time (Project Month) must the following be


issued/done to support the Project execution?

P&ID 1st issue


LLI Material Requisition Issued for Purchase
HAZOP
Control valves, PSVs PO
issue of Plot Plan IFC
issue of IFC P&Ids
50% ISOs issued
2014 Herv Baron

HERVE
BARON

Typical level 1 On-Shore EPC Project Engineering schedule

2014 Herv Baron

Training Agenda
Day 3

HERVE
BARON

The main challenge: meeting the Project schedule


FEED
EPC

How to control a Contractor


The plan
Progress measurement
Factors that could Impact progress
Engineering Controls and KPIs
Engineering Quality
Critical Points to watch

2014 Herv Baron

HERVE
BARON

Safety Engineering

2014 Herv Baron

In your opinion, how is Safety performing?

Training Agenda
Day 3

HERVE
BARON

The main challenge: meeting the Project schedule


FEED
EPC

How to control a Contractor


The plan
Progress measurement
Factors that could Impact progress
Engineering Controls and KPIs
Engineering Quality
Critical Points to watch

2014 Herv Baron

HERVE
BARON

Engineering progress KPIs

2014 Herv Baron

HERVE
BARON

EPC Key Engineering Milestones and benchmarks

Key Engineering Milestones for an EPC


P&ID 1st issue
LLI PO
HAZOP
1st model review
1st Piping PO
Control valves, PSVs PO
Plot Plan IFC
IFC P&IDs
50% ISOs
Primary steel MTO
Primary steel drawings IFC

Additional Milestones for Off-Shore jobs


2014 Herv Baron

Engineering Manhours benchmarks

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BARON

FEED: number of Home Office (H.O.) manhours per equipment


item
??? hours

EPC: number of H.O. manhours per equipment item


??? hours

EPC: number of H.O. manhours per USD of CAPEX?


??? hour / mln USD

EPC: number of Procurement (Buyer, Expediter, Inspector,


Transit) manhours for one Purchase Order?

Please guess

2014 Herv Baron

???? manhours

Engineering Management Training

HERVE
BARON

Your instructor:
Herv Baron, Project Manager
Professional experience/positions held

Process Engineer (2 years), Production Engineer (2 years)

Engineering Manager (4 years) for EPC On-Shore 300mln USD Project

Field Engineering Manager (4 years) for EPC Off-shore (FPSO) 1bln USD Project

Project Manager (2 years) for 50mln USD EPC revamping

Project Manager (1 year) for FEED and Basic Design

Project Control Manager (1 year) for 100,000 manhours FEED

Contract Manager (3 years) for 700mln USD and 1bln USD EPC

Professional experience/Companies worked with

Developer and instructor of IFP Trainings

TOTAL, for 4 years

Engineering Management Training (10 sessions held),

SAIPEM, for 8 years

Project control training (6 sessions held),

TECHNIP, for 6 years

2014 Herv Baron

Training experience

2015 Training schedule

HERVE
BARON

3 training sessions will be held in 2015:

Paris: May 26-28, September 2-4

For details and to enroll please go to:

http://www.ifptraining.com/course/engineering-management-5219.html

Lombok (near Bali), Indonesia: Oct 20-23

For details and to enroll please go to:


http://rhenindo.com/trainings/barons-oil-and-gas-engineering-management/

2014 Herv Baron

Pick the location you like!

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