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The execution of a Complex


Project a guided tour

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The
COMPANY
Client

The actors

The suppliers

The EPC
Contractor

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The sub-contractors

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The phases

Sanction

Basic Engineering
By ENGINEERING

Project Execution
by EPC CONTRACTOR

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Conceptual evaluation
+ Pre-Project
By COMPANY

Sanction

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Design

Procurement

Manufacturing

Installation

Construction &
erection

Inspection & tests

Shipping

Hand-over

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The multiple sides of a Project

Project Control

PROJECT

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Human Resources Management

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The multiple sites of a Project


Home office (Paris)
Project management
Detail Engineering (part)
Procurement

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

Shipyard (Korea)
Hull Engineering & Fabrication

Satellite office
Detail Engineering (part)

Fabrication yard (Nigeria):


Fabrication (part)

Installation, commissioning, start-up

Shipyards (Singapore &


Malaysia)
Topsides Fabrication & Integration

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Offshore (Nigeria):

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Project

Engineering

Procurement

Construction

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Project

Engineering

Procurement

Construction

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The facilities design basis


Infrastructure:

Feedstock and products flow


Feedstock composition
Battery limit conditions

Pressure (bar)

Process facilities:

50

Administrative and technical


buildings

45
40

Control room

35

Access road

30

Equipment Spare

Site fencing, gates, check point

25
20

Performance:
Products specifications

15

Design criteria:

10

% of over design

Energy efficiency, emissions

0
-85

-80

-75

-70

-65

-60

-55

Environment data:

Utilities:

Min/max temperature

Electric power supply

Rain/snow fall

Other utilities

Wind
Geological conditions

Process control

Applicable codes and standards:

Fire/gas alarm

International standards

Public address, LAN, PABX

Local rules

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Systems:

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Engineering
in the Project

Design basis:

Documents for Construction:

- Functional
requirements

Construction drawings &


specifications

- Client
specifications

Engineering

Documents for Purchase:


bill of quantity & specification

- Design codes
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Project

Instruments&
Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Project

Instruments&
Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Process simulations

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Thermodynamic
calculations

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Process Flow
Diagram (PFD)

Heat & Material


balance

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Equipment list

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Equipment
duty

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Process data sheet

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Process Flow Diagram (PFD)

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Piping & Instrumentation Diagram (P&ID)

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Piping &
Instrumentation
Diagram (P&ID)

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Process control

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Emergency shut down

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Emergency relief

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Operating manual

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Project

Instruments&
Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Rotating machinery

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Pressure vessels

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Heat exchangers

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Packages,
Fired Equipment

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Process data
sheet
Mechanical
data sheet

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Material Requisition

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Project

Instruments&
Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Fire fighting

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Passive fire protection

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Fire & Gas detection layout

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Environmental Impact Assessment

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Project

Instruments&
Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Equipment supporting
structures

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Piping supporting
structures (pipe-racks)

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Structural design

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Structural design

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Structural
drawings

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Architectural drawings

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Equipment layout
drawing

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Project

Instruments&
Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Layout/
principles

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Layout/consideration for all networks

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General Plot Plan

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Piping Layout
drawing
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3D modelling

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3D model clash check

3D model review
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Piping Design

Design code for Process plants: ASME B31.3

P*D
t=
(2SWE + PY)
P design pressure
D (outside) diameter
S stress value for material as per table in ASME B31.3
W weld joint reduction factor for long term strength of weld at elevated temperature
E quality factor, from table in ASME B31.3 (1 for seamless, 0.85 for ER welded pipe, etc.)
Y coefficient from table in ASME B31.3 (from 0.4 to 0.7 depending on material and
temperature)
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To the above calculated thickness shall be added:


- The corrosion allowance, e.g., 3 mm
- The manufacturing tolerance: 12.5%

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Thickness (mm) Number of passes

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Isometric drawing

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Piping Pre-fabrication

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Piping General
Arrangement drawing

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Standard Pipe Support


drawings

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Material Selection

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Material Specification

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Material Specification

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Project

Instruments&
Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Instrument data sheet

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Process Control System

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System architecture
drawing

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Mechanical Equipment Control

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The instrumentation hardware


Instrument room
Marshalling

Controller

cabinet

cabinet

Control room

VDU

PT

JB

Process
line

CPU

LAN
Secondary cable
Multi cable

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Building detail drawing/Telecom and PAGA layout

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Cable routing drawings

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Cable list

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Cable routing inside technical rooms

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Project

Instruments&
Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Electrical consumers list

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Electrical Load Summary

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Electrical distribution

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General One
Line Diagram

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Generators

Equipment
specification

Switchgear

Transformer
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Electrical equipment layout

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Electrical
Control System

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Process design
PFDs
H&M balance

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Process design
PFDs
H&M balance

Process
data sheet

Equipment specification

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Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.

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Process design
PFDs

P&IDs

H&M balance

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Process design
PFDs

P&IDs

H&M balance

Piping
Instrumentation

Process
data sheet

Equipment specification
Vendor
drawings

Layout
Civil
Electrical

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Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.

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Engineering work sequence

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Typical 3 year EPC Project Engineering schedule

PR = Process,
EQ = Equipment,
PL = Plant Layout,
PI = Piping,
I&C = Instrumentation
& Control,
EL = ELectrcial,
HSE = Safety &
Environment,
CIV = Civil

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Process design
PFDs

P&IDs

H&M balance

Piping
Instrumentation

Process
data sheet

Equipment specification
Vendor
drawings

Layout
Civil
Electrical

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Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.

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Electrical
Layout
Piping

Vendor

Instrumentation &
Control
Process

Civil

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Engineering / Vendor interfaces

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Electrical

Process
Utility consumption

Power consumption

Battery limit conditions

General
Arrangement

Layout

P&ID

Vendor

Piping

Functional analysis
C&E

Instrumentation
& Control

Terminals dwgs
Purchaser Mechanical
connection list and
dwg

Civil

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Foundation drawing and loads,


including auxiliaries!

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Interested and wanting to know more on Engineering?

A unique synthesis for


the busy Project
professional
270 pages
300 illustrations

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The Oil & Gas Engineering Guide - 2nd edition

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Read on-line:
http://www.readoz.com/publication/read?i=1065872#page1

The Oil & Gas Engineering Guide


2nd edition

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Up to March 30th, 2015 the Guide can be


purchased at a 25% discounted price of:

EUR 49 / USD 54 on the publichers


website:

http://www.editionstechnip.com/en/catal
ogue-detail/1111/oil-gas-engineeringguide-the.html

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Project

Engineering

Procurement

Construction

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Procurement

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Procurement / Steps

Inquiry (Call for Tender)


Short listing
Bid analysis
Clarifications
Negotiations
Purchase Order
Expediting
Inspection

Warranty Period

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Delivery

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Procurement / Supplier selection criteria


Technical Compliance
Price
Qualification of supplier
Schedule
Load of workshop
References
References with final Client
Financial situation

Internal feed-back

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Annual turn-over

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Procurement

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Expediting

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Expediting

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Inspection

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Inspection

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Shipping
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Shipping
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Shipping
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Project

Engineering

Procurement

Construction

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Earthworks

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Pipeline
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Pipeline
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Roads
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Buildings
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Civil Works

Sand
Aggregate

Cement
Admixtures
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Civil Works

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Civil Works

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Civil Works

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Civil Works

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Civil Works

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Pre-fabrication

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Erection
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Underground networks

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Plant erection

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Steel structure erection

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Equipment installation

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Equipment installation

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Piping Pre-fabrication

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Piping erection

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Piping erection

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Field Instrumentation Installation

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Electrical equipment connection

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Cable pulling

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Arrangement of Technical rooms

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Cable connections

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Other Systems Field Equipment Installation

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Control room consoles installation

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Testing
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Commissioning
Handover System

Sub-System
Document Folder

Circuit

Elect Equip

Mech Equip
Instrument
Loop

Instrument
Cable

Instrument
Tag

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Junction
Box

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The multiple sides of a Project

Project Control

PROJECT

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Human Resources Management

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Project Organisation

Project
Manager

Engineering
Manager

Project
Engineers

Procurement
Manager

Discipline
Engineers

Process

Civil

Instrumentation

Electrical

Expediters

Inspectors

Construction
Manager

Contract
Manager

Scheduling
Manager

Cost Control

Construction
Superintendent

Construction
supervisor

Construction
superintendent

Construction
supervisor
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Equipment

Purchasers

Project Control
Manager

Site Manager

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Project procedures

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Project temporary facilities

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Project temporary facilities

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Project temporary facilities

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Project temporary facilities

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Project temporary facilities

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Construction Procedures

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Quality Control

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Quality Control

Temperature

Sampling
Slump
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Quality Control

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Cost Control

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Insurance
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Contracts

P.O.

P.O.

Purchase
Orders

P.O.

EPC
Main Contract

Sub-Contracts

Sub

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Sub

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Contracts
Terms and
Conditions
Price
Schedule

EPC
Main Contract

Performance
guarantees
Technical
basis
Specifications,
codes & stds
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Contracts

E P C
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Contracts

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+ x%

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Construction contracts

Civil

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Construction contracts

Mechanical

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Construction contracts

E&I

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Construction contracts

General
Contractor
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Contracts
Terms and Conditions

EPC
Main Contract

Obligations of the 2 parties


Penalties in case of bad performance
Conflict resolution

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Limit of liability

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Quality Assurance (QA)

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Quality Assurance (QA)

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Quality Assurance (QA)

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Quality Assurance (QA)

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Document Control
Document code
1

Installation drawings

Detail drawings

Diagrams

Lists Bill of Quantities

Isometrics

Calculation notes

Specifications

Data sheets

Requisitions
Discipline code
Instrumentation & Control

Civil engineering

Electrical

Project general documents

Mechanical

Safety

Piping & Layout

Processes

Steel Structures

Vessels Heat exchangers

Materials Welding

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Document Control

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Document Control
Client
Documents
submitted
to client

Approval/
Comments

Engineering

Comments

Vendors

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Documents
submission

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Electronic Document Management System

Center 1 Sr.
Mgmt

Intranet /
Internet

Center 2 Sr.
Mgmt

Correspondence
etc.

Electronic Document
Management System
Projects

Breakdown
structures

Engineering
documents

Reports
Interfaces

Satellite
Engineering
Center

Vendor
documents
Construction
Site

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Intranet /
Internet

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Interface Management

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Scheduling

MONTH
PROJECT SCHEDULE
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
PLANT START-UP
PIPING PRE-FABRICATION & INSTALLATION
X X X X X X X X X X
PIPING MATERIAL & DRAWINGS AT SITE
PIPING MATERIAL MANUFACTURING & SHIPPING
X X X X X X
PURCHASE OF PIPING MATERIAL
TECHNICAL & COMMERCIAL CLARIFICATIONS
X X
CALL FOR TENDER FOR PIPING MATERIAL
PREPARE PIPING MATERIAL TAKE-OFF
X
PIPING ROUTING STUDIES
X X X
PIPING & INSTRUMENTATION DIAGRAMS (PIDs)

2 3

2
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Critical path of an Oil & Gas Project

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Progress Monitoring
How would you measure
progress?

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Progress Monitoring

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Progress Monitoring

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Progress Monitoring

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IT

Today: 3D
15 years ago: 2D

Tomorrow:
3D & data

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IT
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Safety
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Safety

Guard Rail System with Toe


Boards

Planking

Runner

Bearer

Post

Cross Bracing

Longitudinal Brace

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Sill

Safety
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Human resources / career path


Graduate Engineer, 25 years old

Process Engineer

Project Engineer

Engineering Manager/
Deputy Project Manager

Project Manager

3-5 yrs

5 yrs

5-7 yrs

40-45 yrs old


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Note: the career pattern shown here is a very fast track one to the PM
position... One would enjoy oneself just as well taking more time!

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The Oil & Gas Engineering Guide


2nd edition

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

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The Oil & Gas Engineering Guide - 2nd edition


Table of Contents

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The Oil & Gas Engineering Guide


2nd edition

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BARON

Up to March 30th, 2015 the Guide can be


purchased at a 25% discounted price of:

EUR 49 / USD 54 on the publichers


website:

http://www.editionstechnip.com/en/catal
ogue-detail/1111/oil-gas-engineeringguide-the.html

2015 Herv Baron