EPC Project Execution Orientation Course

BARON©

The execution of a Complex Project…

A guided tour

BARON©

The actors

The COMPANY

“Client”The EPC

Contractor

The suppliers

The sub-contractors

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Conceptual evaluation+ Pre-Project

By COMPANY

Basic EngineeringBy ENGINEERING

Project Executionby EPC CONTRACTOR

Sanction Sanction

The phases

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nDesign Procurement Manufacturing Shipping

InstallationConstruction & erection

Inspection & tests

Hand-over

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nThe multiple sides of a Project

urces M

Project Control

PROJECT

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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

BARON©

Project

Engineering Procurement Construction

BARON©

Project

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

Geological conditions

Applicable codes and standards:

International standards

Local rules

10 15 20 25 30 35 40 45 50

-85 -80 -75 -70 -65 -60 -55 P

The facilities design basis

BARON©

EngineeringDocuments for Purchase:

bill of quantity & specification

Documents for Construction:

Construction drawings & specifications

Design basis:

- Functional requirements

- Client specifications

- Design codes

Engineeringin the Project

BARON©

Project

Engineering

Instruments& Control

Layout& Piping

Process Electrical Equipment Civil Safety

Procurement Construction

BARON©

Project

Engineering

Layout& Piping

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nProcess simulations

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nHeat & Material balance

Thermodynamic calculations

Process Flow Diagram (PFD)

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nEquipment list

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Equipment duty

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Process data sheet

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nProcess 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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nProcess control

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nEmergency shut down

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nEmergency relief

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nOperating manual

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Project

Engineering

Layout& Piping

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Rotating machinery

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nPressure vessels

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Heat exchangers

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nPackages,

Fired Equipment

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Process data sheet

Mechanical data sheet

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nMaterial Requisition

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Project

Engineering

Layout& Piping

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nFire fighting

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nPassive fire protection

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nFire & Gas detection layout

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Environmental Impact Assessment

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Project

Engineering

Layout& Piping

BARON©

Equipment supporting structures

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Piping supporting structures (pipe-racks)

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nStructural design

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Structural drawings

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Architectural drawings

Equipment layout drawing

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Project

Engineering

Layout& Piping

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Layout/

principles

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nLayout/consideration for all networks

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General Plot Plan

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Piping Layout drawing

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n3D modelling

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3D model review

3D model clash check

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

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

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nThickness (mm) Number of passes

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nIsometric drawing

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Piping Pre-fabrication

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Piping General Arrangement drawing

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nStandard Pipe Support drawings

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nMaterial Selection

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nMaterial Specification

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Material Specification

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Project

Engineering

Layout& Piping

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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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Process line

Marshalling

cabinet

Controller

cabinet

Instrument room Control room

LANSecondary cable

Multi cable

The instrumentation hardware

BARON©

Building detail drawing/

Telecom and PAGA layout

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Cable routing drawings

Cable list

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nCable routing inside technical room

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Project

Engineering

Layout& Piping

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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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nElectrical equipment layout

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Electrical Control System

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Process design

H&M balance

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Process design

H&M balance

Rotating

Pressure vessels

Fired equipment

Heat exchangers

Packages etc.

Process

data sheet

Equipment specification

BARON©

Process design

H&M balance

BARON©

Process design

H&M balance

Rotating

Pressure vessels

Fired equipment

Heat exchangers

Packages etc.

Piping

Instrumentation

Layout

Electrical

Process

data sheet

Vendor

drawings

BARON©

Process design

H&M balance

Rotating

Pressure vessels

Fired equipment

Heat exchangers

Packages etc.

Piping

Instrumentation

Layout

Electrical

Process

data sheet

Vendor

drawings

BARON©

Vendor

Instrumentation &

Control

Electrical

Layout

PipingProcess

BARON©

What Engineering designed

What the Vendor supplied

BARON©

Field Engineering

BARON©

nA unique synthesis for the busy Project professional200 pages, 250 illustrations

Interested and wanting to know more on Engineering?

BARON©

Project

BARON©

nProcurement

BARON©

Inquiry (Call for Tender)

Short listing

Bid analysis

Clarifications

Negotiations

Purchase Order

Expediting

Inspection

Delivery

Warranty Period

Procurement / Steps

BARON©

nProcurement / Supplier selection criteria

Technical Compliance

Qualification of supplier

Schedule

Load of workshop

References

References with final Client

Financial situation

Annual turn-over

Internal feed-back

BARON©

nProcurement

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nExpediting

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nExpediting

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nInspection

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nInspection

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Project

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nEarthworks

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nBuildings

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Admixtures

Aggregate

Cement

Civil Works

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nCivil Works

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nCivil Works

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nCivil Works

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nCivil Works

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nCivil Works

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nPre-fabrication

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nUnderground networks

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nPlant erection

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nSteel structure erection

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nEquipment installation

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nEquipment installation

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nPiping Pre-fabrication

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nPiping erection

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nPiping erection

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nField Instrumentation Installation

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nElectrical equipment connection

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nCable pulling

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nArrangement of Technical rooms

BARON©

nCable connections

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nOther Systems Field Equipment Installation

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nControl room consoles installation

BARON©

Sub-System

Junction

Instrument

Mech Equip

Document Folder

Handover System

Elect EquipCircuit

Instrument

Commissioning

BARON©

nThe multiple sides of a Project

urces M

Project Control

PROJECT

BARON©

nProject Organisation

Project Manager

Engineering Manager

Project Engineers

Discipline Engineers

Process

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

BARON©

nProject procedures

BARON©

nProject temporary facilities

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nConstruction Procedures

BARON©

nQuality Control

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SamplingTemperature

Quality Control

BARON©

nQuality Control

BARON©

nCost Control

BARON©

nInsurance

BARON©

nContracts

Main Contract

Purchase

Orders

Sub-Contracts

BARON©

nContracts

Main Contract

Terms and Conditions

Schedule

Performance guarantees

Technical basis

Specifications, codes & stds

BARON©

nContracts

BARON©

nContracts

BARON©

nContracts

BARON©

nContracts

∑ + x%

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nConstruction contracts

BARON©

Mechanical

BARON©

General Contractor

BARON©

ContractsTerms and Conditions

Main Contract

Obligations of the 2 parties

Limit of liability

Penalties in case of bad performance

Conflict resolution

BARON©

nQuality Assurance (QA)

BARON©

Quality Assurance (QA)

Email vs Technical Query…

BARON©

Unformal/Unrecoverable!

Formal/Recoverable!

BARON©

Unformal/Unrecoverable!

Formal/Recoverable!

Think of somebody trying to find out what was CPY decision in 3 years time...

BARON©

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

BARON©

nDocument Control

BARON©

nDocument Control

Engineering

Documents submitted to client

Client

Approval/

Comments

Vendors

Documents submission

Comments

BARON©

Intranet / Internet

Breakdown structures

Projects

Interfaces

Reports

Satellite Engineering

Center

Center 1 Sr. Mgmt Center 2 Sr.

Construction Site

Electronic Document

Management System

Engineering

documents

Vendor

documents

Correspondence

Electronic Document Management System

BARON©

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 33 34 35 36PLANT START-UPPIPING PRE-FABRICATION & INSTALLATION X X X X X X X X X XPIPING MATERIAL & DRAWINGS AT SITEPIPING MATERIAL MANUFACTURING & SHIPPING X X X X X XPURCHASE OF PIPING MATERIALTECHNICAL & COMMERCIAL CLARIFICATIONS X XCALL FOR TENDER FOR PIPING MATERIALPREPARE PIPING MATERIAL TAKE-OFF XPIPING ROUTING STUDIES X X XPIPING & INSTRUMENTATION DIAGRAMS (PIDs)

PROJECT SCHEDULEMONTH

Scheduling

BARON©

nScheduling

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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

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Safety

Guard Rail System with ToeBoards

Cross Bracing

Planking

Runner

Bearer

Longitudinal Brace

BARON©

Human resources / career path

3-5 yrs

Graduate Engineer, 25 years old

5-7 yrs

40-45 yrs oldProject Manager

Engineering Manager/Deputy Project Manager

Project Engineer

Process Engineer

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!

BARON©

Beyond this presentation…

http://www.toblog.fr/en/baron.html

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EPC Project Execution Orientation Course

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