The execution of a Complex Project A guided tour

Transcription

1 The execution of a Complex Project A guided tour

2 The COMPANY Client The actors The EPC Contractor The suppliers The sub-contractors

3 The phases Sanction Sanction Conceptual evaluation + Pre-Project By COMPANY Basic Engineering By ENGINEERING Project Execution by EPC CONTRACTOR

4 Design Procurement Manufacturing Shipping Installation Construction & erection Inspection & tests Hand-over

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

6 Home office (Paris) Project management Detail Engineering (part) Procurement The multiple sites of a Project Engineering Sub-Contractor (India) Detail Engineering (part) 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

7 Project Engineering Procurement Construction

8 Project Engineering Procurement Construction

9 The facilities design basis Process facilities: Feedstock and products flow Feedstock composition Battery limit conditions Equipment Spare Pressure (bar) Infrastructure: Administrative and technical buildings Control room Access road Site fencing, gates, check point Performance: Products specifications Energy efficiency, emissions Design criteria: % of over design Utilities: Electric power supply Other utilities Environment data: Min/max temperature Rain/snow fall Wind Systems: Process control Fire/gas alarm Public address, LAN, PABX Geological conditions Applicable codes and standards: International standards Local rules

10 Engineering in the Project Design basis: - Functional requirements - Client specifications - Design codes Engineering Documents for Construction: Construction drawings & specifications Documents for Purchase: bill of quantity & specification

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

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

13 HERVE Process simulations

14 Thermodynamic calculations Heat & Material balance Process Flow Diagram (PFD)

15 HERVE Equipment list

16 HERVE Equipment duty

17 HERVE Process data sheet

18 Process Flow Diagram (PFD)

19 Piping & Instrumentation Diagram (P&ID)

20 Piping & Instrumentation Diagram (P&ID)

21 HERVE Process control

22 HERVE Emergency shut down

23 HERVE Emergency relief

24 HERVE Operating manual

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

26 Rotating machinery HERVE

27 HERVE Pressure vessels

28 HERVE Heat exchangers

29 HERVE Packages, Fired Equipment

30 Process data sheet Mechanical data sheet

31 HERVE Material Requisition

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

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35 HERVE Fire fighting

36 Passive fire protection HERVE

37 Fire & Gas detection layout

38 Environmental Impact Assessment

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

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44 Equipment supporting structures

45 Piping supporting structures (pipe-racks)

46 HERVE Structural design

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48 HERVE Structural drawings

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50 Architectural drawings Equipment layout drawing

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

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54 Layout/ HERVE principles

55 Layout/consideration for all networks

56 General Plot Plan HERVE

57 Piping Layout drawing HERVE

58 HERVE 3D modelling

59 3D model clash check 3D model review

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

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

63 Thickness (mm) Number of passes

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68 HERVE Isometric drawing

69 Piping Pre-fabrication HERVE

70 Piping General Arrangement drawing

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72 Standard Pipe Support drawings

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74 HERVE Material Selection

75 Material Specification HERVE

76 Material Specification HERVE

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

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79 HERVE Instrument data sheet 2013 Hervé Baron

80 HERVE Process Control System

81 System architecture drawing

82 Mechanical Equipment Control

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

84 Building detail drawing/ Telecom and PAGA layout

85 Cable routing drawings Cable list

86 Cable routing inside technical room

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

88 Electrical consumer list HERVE

89 Electrical Load Summary HERVE

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91 HERVE General One Line Diagram

92 HERVE Generators Single line diagram Switchgear Transformer 2013 Hervé Baron

93 Electrical equipment layout

94 HERVE Electrical Control System

95 Process design PFDs H&M balance

96 Process design PFDs H&M balance Process data sheet Equipment specification Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

97 Process design PFDs P&IDs H&M balance

98 Process design PFDs P&IDs H&M balance Piping Instrumentation Process data sheet Equipment specification Rotating Pressure vessels Fired equipment Heat exchangers Packages etc. Vendor drawings Layout Civil Electrical

99 Process design PFDs P&IDs H&M balance Piping Instrumentation Process data sheet Equipment specification Rotating Pressure vessels Fired equipment Heat exchangers Packages etc. Vendor drawings Layout Civil Electrical

100 Layout Piping Electrical Vendor Civil Instrumentation & Control Process

101 What the Vendor supplied What Engineering designed

102 HERVE Field Engineering

103 Interested and wanting to know more on Engineering? A unique synthesis for the busy Project professional 200 pages, 250 illustrations

104 Project Engineering Procurement Construction

105 HERVE Procurement

106 Procurement / Steps Inquiry (Call for Tender) Short listing Bid analysis Clarifications Negotiations Purchase Order Expediting Inspection Delivery Warranty Period

107 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

108 HERVE Procurement

109 HERVE Expediting

110 HERVE Expediting

111 HERVE Inspection

112 HERVE Inspection

113 HERVE Shipping

114 HERVE Shipping

115 HERVE Shipping

116 Project Engineering Procurement Construction

117 HERVE Earthworks

118 HERVE Pipeline

119 HERVE Pipeline

120 HERVE Roads

121 HERVE Buildings

122 Civil Works Sand Aggregate Cement Admixtures

123 HERVE Civil Works

124 HERVE Civil Works

125 HERVE Civil Works

126 HERVE Civil Works

127 HERVE Civil Works

128 HERVE Pre-fabrication

129 HERVE Erection

130 HERVE Underground networks

131 HERVE Plant erection

132 HERVE Steel structure erection

133 HERVE Equipment installation

134 HERVE Equipment installation

135 HERVE Piping Pre-fabrication

136 HERVE Piping erection

137 HERVE Piping erection

138 Field Instrumentation Installation

139 Electrical equipment connection

140 HERVE Cable pulling

141 Arrangement of Technical rooms

142 HERVE Cable connections

143 Other Systems Field Equipment Installation

144 Control room consoles installation

145 HERVE Testing

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

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

148 Project Organisation Project Manager Engineering Manager Procurement Manager Site Manager Project Control Manager Project Engineers Discipline Engineers Purchasers Expediters Inspectors Construction Manager Contract Manager Scheduling Manager Cost Control Process Construction Superintendent Civil Construction supervisor Instrumentation Construction superintendent Electrical Construction supervisor Equipment

149 HERVE Project procedures

150 Project temporary facilities

151 Project temporary facilities

152 Project temporary facilities

153 Project temporary facilities

154 Project temporary facilities

155 HERVE Construction Procedures

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157 HERVE Quality Control

158 Quality Control Temperature Sampling Slump

159 HERVE Quality Control

160 HERVE Cost Control

161 HERVE Insurance

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

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

164 HERVE E Contracts

165 HERVE Contracts E P

166 HERVE Contracts E P C

167 + x% HERVE Contracts

168 Construction contracts Civil

169 Construction contracts Mechanical

170 HERVE Construction contracts E&I

171 Construction contracts General Contractor

172 Contracts Terms and Conditions EPC Main Contract Obligations of the 2 parties Limit of liability Penalties in case of bad performance Conflict resolution

173 HERVE Quality Assurance (QA)

174 HERVE Quality Assurance (QA)

175 Quality Assurance (QA) vs Technical Query

176 Quality Assurance (QA) Unformal/Unrecoverable! vs Technical Query Formal/Recoverable!

177 Quality Assurance (QA) Unformal/Unrecoverable! vs Technical Query Formal/Recoverable! Think of somebody trying to find out what was CPY decision in 3 years time...

178 HERVE Quality Assurance (QA)

179 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 A C E G J K M P S V W Discipline code Instrumentation & Control Civil engineering Electrical Project general documents Mechanical Safety Piping & Layout Processes Steel Structures Vessels Heat exchangers Materials Welding

180 HERVE Document Control

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

182 Electronic Document Management System Center 1 Sr. Mgmt Intranet / Internet Center 2 Sr. Mgmt Correspondence etc. Electronic Document Management System Breakdown structures Projects Reports Engineering documents Interfaces Satellite Engineering Center Intranet / Internet Construction Site Vendor documents

183 HERVE Interface Management

184 Scheduling MONTH PROJECT SCHEDULE PLANT START-UP 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 TECHNICAL & COMMERCIAL CLARIFICATIONS X X CALL FOR TENDER FOR PIPING MATERIAL 2 3 PREPARE PIPING MATERIAL TAKE-OFF X PIPING ROUTING STUDIES 1 X X X PIPING & INSTRUMENTATION DIAGRAMS (PIDs)

185 HERVE Scheduling

186 Progress Monitoring How would you measure progress?

187 HERVE Progress Monitoring

188 HERVE Progress Monitoring

189 HERVE Progress Monitoring

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

191 HERVE IT

192 HERVE Safety

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

194 HERVE Safety

195 Human resources / career path Graduate Engineer, 25 years old Process Engineer 3-5 yrs Project Engineer 5 yrs Engineering Manager/ Deputy Project Manager 5-7 yrs Project Manager 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!

196 Beyond this presentation Share my new developments Find my other on-line and classroom training