EPC Project Execution projects manufacturing

Epc

1. HERVE
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© 2013 – Hervé Baron
The execution of a Complex Project…
A guided tour
HERVE
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2. HERVE
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© 2013 – Hervé Baron
The actors
The
COMPANY
“Client”
The EPC
Contractor
The suppliers
The sub-contractors

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© 2013 – Hervé Baron
Conceptual evaluation
+ Pre-Project
By COMPANY
Basic Engineering
By ENGINEERING
Project Execution
by EPC CONTRACTOR
Sanction
Sanction
The phases

4. HERVE
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© 2013 – Hervé Baron
Design
Procurement
Manufacturing
Shipping
Installation
Construction
& erection
Inspection &
tests
Hand-over

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© 2013 – Hervé Baron
The multiple sides of a Project
Human Resources Management
Project Control
PROJECT

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© 2013 – 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

7. HERVE
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© 2013 – Hervé Baron
Project
Engineering
Procurement
Construction

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© 2013 – Hervé Baron
Project
Engineering
Procurement
Construction

9. HERVE
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© 2013 – 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

Pressure (bar)
The facilities design basis

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© 2013 – 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

11. HERVE
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© 2013 – Hervé Baron
Project
Engineering
Instruments&
Control
Layout
& Piping
Process
Electrical
Equipment
Civil
Safety
Procurement
Construction

12. HERVE
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© 2013 – Hervé Baron
Project
Engineering
Instruments&
Control
Layout
& Piping
Process
Electrical
Equipment
Civil
Safety
Procurement
Construction

13. HERVE
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© 2013 – Hervé Baron
Process simulations

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© 2013 – Hervé Baron
Heat & Material
balance
Thermodynamic
calculations Process Flow
Diagram (PFD)

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© 2013 – Hervé Baron
Equipment list

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© 2013 – Hervé Baron
Equipment
duty

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© 2013 – Hervé Baron
Process data sheet

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© 2013 – Hervé Baron
Process Flow Diagram (PFD)

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© 2013 – Hervé Baron
Piping & Instrumentation Diagram (P&ID)

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Piping &
Instrumentation
Diagram (P&ID)

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Process control

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© 2013 – Hervé Baron
Emergency shut down

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Emergency relief

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Operating manual

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© 2013 – Hervé Baron
Project
Engineering
Instruments&
Control
Layout
& Piping
Process
Electrical
Equipment
Civil
Safety
Procurement
Construction

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© 2013 – Hervé Baron
Rotating machinery

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© 2013 – Hervé Baron
Pressure vessels

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© 2013 – Hervé Baron
Heat exchangers

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© 2013 – Hervé Baron
Packages,
Fired Equipment

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© 2013 – Hervé Baron
Process data
sheet
Mechanical
data sheet

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© 2013 – Hervé Baron
Material Requisition

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© 2013 – Hervé Baron

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© 2013 – Hervé Baron
Project
Engineering
Instruments&
Control
Layout
& Piping
Process
Electrical
Equipment
Civil
Safety
Procurement
Construction

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35. HERVE
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© 2013 – Hervé Baron
Fire fighting

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© 2013 – Hervé Baron
Passive fire protection

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© 2013 – Hervé Baron
Fire & Gas detection layout

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© 2013 – Hervé Baron
Environmental Impact Assessment

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© 2013 – Hervé Baron
Project
Engineering
Instruments&
Control
Layout
& Piping
Process
Electrical
Equipment
Civil
Safety
Procurement
Construction

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© 2013 – Hervé Baron

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Equipment supporting
structures

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© 2013 – Hervé Baron
Piping supporting
structures (pipe-racks)

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© 2013 – Hervé Baron
Structural design

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© 2013 – Hervé Baron

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© 2013 – Hervé Baron
Structural
drawings

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© 2013 – Hervé Baron

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© 2013 – Hervé Baron
Architectural drawings
Equipment layout
drawing

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52. HERVE
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© 2013 – Hervé Baron
Project
Engineering
Instruments&
Control
Layout
& Piping
Process
Electrical
Equipment
Civil
Safety
Procurement
Construction

53. HERVE
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© 2013 – Hervé Baron

54. HERVE
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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 review
3D model clash check

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Piping Design
ANSI B31.8 (for gas pipelines and
compressor stations)

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© 2013 – Hervé Baron
Piping Design
ANSI B31.8 (for gas pipelines and
compressor stations)

63. HERVE
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© 2013 – Hervé Baron
Thickness (mm) Number of passes

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© 2013 – Hervé Baron

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© 2013 – Hervé Baron

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Isometric drawing

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© 2013 – Hervé Baron
Piping Pre-fabrication

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Piping General
Arrangement drawing

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Standard Pipe Support
drawings

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© 2013 – Hervé Baron

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Material Selection

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Material Specification

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© 2013 – Hervé Baron
Material Specification

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© 2013 – Hervé Baron
Project
Engineering
Instruments&
Control
Layout
& Piping
Process
Electrical
Equipment
Civil
Safety
Procurement
Construction

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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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© 2013 – 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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Building detail drawing/
Telecom and PAGA layout

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Cable routing drawings
Cable list

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Cable routing inside
technical room

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Project
Engineering
Instruments&
Control
Layout
& Piping
Process
Electrical
Equipment
Civil
Safety
Procurement
Construction

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© 2013 – Hervé Baron
Electrical consumer list

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Electrical Load
Summary

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General One
Line Diagram

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Generators
Switchgear
Transformer
Single line diagram

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Electrical equipment layout

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Electrical
Control System

95. HERVE
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Process design
PFDs
H&M balance

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© 2013 – Hervé Baron
Process design
PFDs
H&M balance
Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.
Process
data sheet
Equipment specification

97. HERVE
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© 2013 – Hervé Baron
Process design
PFDs
H&M balance
P&IDs

98. HERVE
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© 2013 – 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

99. HERVE
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© 2013 – 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

100. HERVE
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© 2013 – Hervé Baron
Vendor
Instrumentation &
Control
Electrical
Layout
Civil
Piping
Process

101. HERVE
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© 2013 – Hervé Baron
What
Engineering
designed
What the
Vendor
supplied

102. HERVE
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Field Engineering

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© 2013 – Hervé Baron
A unique synthesis for the busy Project professional 200 pages, 250 illustrations
Interested and wanting to know more on Engineering?

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© 2013 – Hervé Baron
Project
Engineering
Procurement
Construction

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© 2013 – Hervé Baron
Procurement

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© 2013 – Hervé Baron
Inquiry (Call for Tender)
Short listing
Bid analysis
Clarifications
Negotiations
Purchase Order
Expediting
Inspection
Delivery
Warranty Period
Procurement / Steps

107. HERVE
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© 2013 – 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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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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© 2013 – Hervé Baron
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

122. HERVE
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Admixtures
Sand
Aggregate
Cement
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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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

133. HERVE
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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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Sub-System
Junction
Box
Instrument
Loop
Instrument
Cable
Mech Equip
Document Folder
Handover System
Elect Equip Circuit
Instrument
Tag
Commissioning

147. HERVE
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© 2013 – Hervé Baron
The multiple sides of a Project
Human Resources Management
Project Control
PROJECT

148. HERVE
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© 2013 – 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

149. HERVE
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© 2013 – Hervé Baron
Project procedures

150. HERVE
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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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157. HERVE
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Quality Control

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Slump
Sampling
Temperature
Quality Control

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Quality Control

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Cost Control

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Insurance

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Contracts
P.O.
Sub
P.O.
P.O.
Main Contract
Purchase
Orders
Sub-Contracts
EPC
Sub

163. HERVE
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© 2013 – Hervé Baron
Contracts
Main Contract
EPC
Terms and
Conditions
Price
Schedule
Performance
guarantees
Technical
basis
Specifications,
codes & stds

164. HERVE
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© 2013 – Hervé Baron
Contracts
E

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Contracts
E P

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Contracts
E P C

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Contracts
∑ + 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
Main Contract
EPC
Obligationsofthe2parties
Limitofliability
Penaltiesincaseofbadperformance
Conflictresolution

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Quality Assurance (QA)

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Quality Assurance (QA)

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Quality Assurance (QA)
Email vsTechnical Query…
Email

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Quality Assurance (QA)
Unformal/Unrecoverable!
Formal/Recoverable!
Email
Email vsTechnical Query…

177. HERVE
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© 2013 – Hervé Baron
Quality Assurance (QA)
Unformal/Unrecoverable!
Formal/Recoverable!
Email
Email vsTechnical Query… Think of somebody trying to find out
what was CPY decision in 3 years time...

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Quality Assurance (QA)

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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

180. HERVE
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Document Control

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Document Control
Engineering
Documents
submitted
to client
Client
Approval/
Comments
Vendors
Documents
submissionComments

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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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Interface Management

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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 3334 35 36
PLANT START-UP
PIPING PRE-FABRICATION & INSTALLATIONX X X X X X X X X X
PIPING MATERIAL & DRAWINGS AT SITE
PIPING MATERIAL MANUFACTURING & SHIPPINGX 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 STUDIESX X X
PIPING & INSTRUMENTATION DIAGRAMS (PIDs)
PROJECT SCHEDULE
MONTH
1
1
2
3
3
4
5
2
4
55
Scheduling

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Scheduling

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

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© 2013 – Hervé Baron
IT

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Safety

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Safety
Guard Rail System with Toe
Boards
Cross Bracing
Planking
Runner
Bearer
Longitudinal Brace
Post
Sill

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Safety

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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 P M position... One would enjoy oneself just as well taking more time!

196. HERVE
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© 2013 – Hervé Baron
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