Engineering Basics

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Basics

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The Engineering Design flow is so much interrelated that an email can never explain its complexity as I dont have tools in email to draw intersecting errows between different activities.Even, if I develop design flow at proposal schedule(The simplest one), I have to draw arrows in different styles to allow crossings between interconnecting lines.In an effort to reply toyour kind email, I am writing reply below in form of simple writing rather drawings.If you wants me to draw a detailed flow, I need two days more because it requires extensive use of Excel tools and atleast two hours.It will take atleast three or seven pages of Excel.I have developed that sketch in my mind.Kindly tell me if you really need that detailed level schedule so I make it.In order to reply your email with full response, I am taking a case of a project, where FEED was not provided by client.

1.In order to develop FEED, first of all we do site visit to check status of existing systems.Once we have checked adequacy and status of existing systems we compare the results with the final desired PRODUCT(Like Gas pressure) of the plant.For example we wants to enahance capacity of an existing Gas processing system to handle raw gas from 40 MMSCFD to 60 MMSCFD at inputs etc.Process department takes lead and It will develop its adequacy study of related systems like IA(Instrument Air system), tanks, Boiler Feed and other systems that need updating in this process.Process also review other documents and systems for adequacy purpose.Process makes a report for all recommended changes; for example, AI system capcaity need to be enhanced.Process will revise all datasheets of old systems(Because their inputs or interrelated variable might change now).Process will identify new systems(Like an additional flare system) and process will develop its Datasheet.After Adequacy study, Process and Piping will start working on a P&IDs(Process) and Plot Plan(Piping) and Tie-In schedule.This activity can be run in parallel with process datasheets development.After Process Datasheets,P&IDs and Plot Plan preparation(Plot Plan:Process and Piping take lead and all other leads participate including construction and commissioning), Piping, I&C, Mechanical and Electrical start working on Datasheets.Piping MTO can also be started at this stage.At completion of this activity, working on RFQ's can be started.During this stage we keep revising our P&ID's for any change.Although P&ID's keep updating till end but major part of change is observed at this stage.This Stage we start Piping Isemetrics, Tie-In schedule, Design of Civil foundations,Trench details, Cable layout, Grounding layout, Load list updating, Cable Schedule, Eletrical MTO etc.SLD can be started at this stage.Work on Construction Drawings is started at this stage.Clarifications and Vdoc review is in process at this stage.

If you need further details, I can draws arrows and boxes in Excel and I will explan through that sheet.

Regarding Progresss of Engineering Deliverables, we assign a percentage to issuance status of deliverables; IFI(Issued for Information,), IFA(issued for approval), IFC(Issued for construction).Like We can give 30% to IFI, 60% to IFA etc.After we have build a consensus with client, we give these parametes to our inhouse software system, lets name it ABC.We develop a long list of documents that are supposed to be issued during our Engineering phase of project.Once a document has reached any level of IFI, IFA or IFC, the system assign it the pre-defined percentage.The accumulated percentage of all documents is combined by software system(simply multilpied).Thats why we get a complete progress status.Since we already have developed complete list of documents and we have assigned estimated manhours to each document so we can easily multiply things and we can calculate our achieved progress, lag and forcasted manhours values.

I hope I have addressed the email fully.If anything is still unanswered, please let me know.

For each possible design option, particularly Plot Plan preparation, we take accessibility of equipment through machines, cranes and personnel into consideration. For each Instrument like Transmitter, we make sure its accessible from operation and maintenance point of view, even its at a very big height, taking one example. For example, if we are installing a transmitter at 12 meter height, we should ensure that its accessible from our available cranes.For each design option, we take O&M cost into consideration and go for the least cost, taking safety first preference.From Constructability point of view, we keep the following points in mind.Schedule is construction sensitive; construction constrains are taken into considerations. For example if Vendor or cranes take one month to reach site, we must take this fact into consideration. If cable laying need 25 labor each day, there is a possibility that 2 out of 8 planned days, we can have shortage of labor and Safety rules will never allow us install heavy weight cable using low number of people; max we can have 25 KG weight on a person.Design is simple so that construction has no issues in implementation.Installation drawings are easy to implement with help of construction sources and machines.Design elements/basics building blocks are standardized so that we can take advantage of repetition.I have spent one year in construction and from my experience, START of any activity is difficult, risky and challenging because your team needs a bit training and working habits at expense of mistakes and time wastage. Once they have completed an activity, its very easy for them to repeat. But if pattern of activity keep changing, then we have to bear their mistakes in each new patterns. We can take example of cable laying here.Design facilitates fabrication, Installation and transportation. For example what to choose from 6 meter and 12 meter pipe length so that we can have a convenient lead time, transportation and construction ease.Environmental conditions has minimal effect on Construction.Specifications are construction friendly.The design should have minimum chances of changes and rework, particularly at construction stage.Design is simple and easy to understand for construction people. It should be closest to previous experiences so that construction people dont take it a new experiment.Engineering teams and Construction team discuss MTO's and BOQ's for each item to minimize costs. More we reduce costs from BOQ's, more we save from construction efforts at later stage. Same is about design.A very important point that is often missed out is analyzing "Integrated Engineering design" from construction point of view. For example, anticipating the possible clashes that may arise from integration of Earthing mesh and foundations of transformers in a switchyard design.Accuracy and availability level of MTOs from Construction point of view.3D model review is major and most important activity from construction, operation and maintenance.Equipment location, Pipe rack information, cable tray information is taken into consideration in 30% model review.Major piping, Major access ways, Pipe support locations, major control panels, Firefighting equipment, Instrument transmitters location is finalized in 60% model review.Rest firm details are finalized in 90% model review.Although 30%, 60% and 90% model review items are decided in consensus with client but I have mentioned above on base of general understanding.Design should be continuously monitored for changes from construction point of view.Architectural drawings, building dimensions, Equipment dimensions, weights, Equipment access requirements, cable entry requirements, Tie-in points(of all types) are major concerns from construction point of view because they have very big impart of decision of construction.MCC building construction delay is frequently observed mistake that delay commissioning.Frequent changes should be avoided in Piping ISO, so that construction can have spooling drawings at earliest and accuracy.I have corrected my CV with dates. Actually, I copied my positions, dates and heading in all sections of my CV and later I edited text of each job description did it to maintain uniformity in pattern of CV.Although I edited all texts but missed dates of last parts. These dates were copy paste of above sections. The attached CV is free from this mistake.Yes, I have spent 1.5 years in Vendor Company, one year in Construction and now 1.2 years in Engineering.