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Slides of Hervé Baron's Engineering Management Training delivered as part of GPA conference on May 16th, 2014 in Leiden

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Gpa presentation

  1. 1. ©2014-IFPTraining Engineering Management Training Engineering Management training GPA’s Leiden conference Knowledge session May 16th, 2014 Having trouble downloading? Go to: http://goo.gl/kIfGP0
  2. 2. ©2014-IFPTraining Training Agenda The Engineering work process • Getting started: Process design • Plant design • Engineering development phases • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  3. 3. ©2014-IFPTraining Training Agenda The Engineering work process • Getting started: Process design • Plant design • Engineering development phases • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  4. 4. ©2014-IFPTraining Process Design Processs scheme selection Oil + gas + water Gas Oil Water Tanker Gas re- injection in reservoir Well HP Separator LP Separator Imagine we have to do the process design of a simple oil production system… What would be the bases of design?
  5. 5. ©2014-IFPTraining Process Design Processs scheme selection Oil + gas + water Gas Oil Water Tanker Gas re- injection in reservoir Well HP Separator LP Separator P T Q xi Pg Vapour pressure spec
  6. 6. ©2014-IFPTraining Process Design Processs scheme selection Oil + gas + water Oil Water Well HP Separator LP Separator How would we optimize the process scheme? Tanker Gas Gas re- injection in reservoirP T Q xi Pg Vapour pressure spec
  7. 7. ©2014-IFPTraining Process Design Processs scheme selection Oil Well HP Separator LP Separator P1 P2T Oil + gas + water Oil Water Gas Tanker Gas re- injection in reservoirP T Q xi Pg Vapour pressure spec
  8. 8. ©2014-IFPTraining Process Design Processs scheme selection HP Separator LP Separator Vapour pressure spec P Q Q W WP T Q xi P T Q xi P1 P2T Pg P T Q xi What would be the output of the Process scheme design?
  9. 9. ©2014-IFPTraining Process Flow Diagram + Heat & Mass Balance
  10. 10. ©2014-IFPTraining Process Design / Sizing of Equipment Tanker HP Separator LP Separator
  11. 11. ©2014-IFPTraining Process Design Equipment sizing Sets the gas cross section Sets the liquid volume Vessel size
  12. 12. ©2014-IFPTraining Process Design Equipment sizing
  13. 13. ©2014-IFPTraining Process Design / Specification of Equipment Tanker HP Separator LP Separator
  14. 14. ©2014-IFPTraining Process Design / Specification of Equipment
  15. 15. ©2014-IFPTraining Training Agenda The Engineering work process • Getting started: Process design • Plant design • Engineering development phases • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  16. 16. ©2014-IFPTraining Plant Design PFD, HMB Process Design
  17. 17. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Process Design
  18. 18. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Process Design Utility consumption Utility Units Design
  19. 19. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Plant Layout Process Design Utility consumption Utility Units Design
  20. 20. ©2014-IFPTraining Plant Design
  21. 21. ©2014-IFPTraining Unit Plot Plan
  22. 22. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Fluids composition & conditions Material selection and specifications Process Design
  23. 23. ©2014-IFPTraining Material Selection Diagram
  24. 24. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Fluids composition & conditions Material selection and specifications Process Design
  25. 25. ©2014-IFPTraining Equipment Mechanical Design
  26. 26. ©2014-IFPTraining Equipment Mechanical Data Sheet
  27. 27. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Fluids composition & conditions Material selection and specifications Equipment design by vendors Process Design
  28. 28. ©2014-IFPTraining Equipment General Arrangement Process Data Sheet Waste Heat Boiler
  29. 29. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Fluids composition & conditions Material selection and specifications Equipment design by vendors Civil design Process Design
  30. 30. ©2014-IFPTraining Civil Foundation Drawings
  31. 31. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Fluids composition & conditions Material selection and specifications Civil design Process Design
  32. 32. ©2014-IFPTraining Piping & Instrumentation Diagram
  33. 33. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Fluids composition & conditions Material selection and specifications Civil design Process Design
  34. 34. ©2014-IFPTraining 3D modelling
  35. 35. ©2014-IFPTraining Piping isometric drawing
  36. 36. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Fluids composition & conditions Material selection and specifications Civil design Structural steel design Process Design
  37. 37. ©2014-IFPTraining Strucutral steel design
  38. 38. ©2014-IFPTraining Strucutral steel design drawings
  39. 39. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Instrumentation & Control design Fluids composition & conditions Material selection and specifications Civil design Structural steel design Process Design
  40. 40. ©2014-IFPTraining Instrumentation design
  41. 41. ©2014-IFPTraining Instrumentation list
  42. 42. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Instrumentation & Control design Fluids composition & conditions Material selection and specifications Civil design Structural steel design Electrical power generation & distribution Process Design
  43. 43. ©2014-IFPTraining Electrical design
  44. 44. ©2014-IFPTraining Electrical design
  45. 45. ©2014-IFPTraining Electrical design Turbogenerator Switchgear Transformer
  46. 46. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Instrumentation & Control design Fluids composition & conditions Material selection and specifications Civil design Structural steel design Electrical power generation & distribution Process Design Do you want to know more?
  47. 47. ©2014-IFPTraining Your reference A unique synthesis 200 pages, 250 illustrations 3000 copies sold to date Browse the book on-line at: http://www.readoz.com/publication/read?i=1025356#page1 Order with a 25% discount voucher at: https://www.dropbox.com/s/845htatxm7cqz8a/Special%20offer%20Leiden.pdf
  48. 48. ©2014-IFPTraining Training Agenda The Engineering work process • Getting started: Process design • Plant design • Engineering development phases • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  49. 49. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Instrumentation & Control design Fluids composition & conditions Material selection and specifications Civil design Structural steel design Electrical power generation & distribution Process Design
  50. 50. ©2014-IFPTraining Engineering Documents for Purchase: bill of quantity & specification Documents for Construction: Drawings & specifications Documents submitted to client Client Approval/ Comments FEED Vendors Documents submission Comments Detailed Engineering Client specs & stds
  51. 51. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Process Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Instrumentation & Control design Fluids composition & conditions Material selection and specifications Civil design Structural steel design Electrical power generation & distribution
  52. 52. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Process Units Design Plant Layout P&IDs Fluids composition & conditions Material selection and specifications Equipment mechanical design
  53. 53. ©2014-IFPTraining Front End Engineering Design (FEED) +/- 10% CAPEX estimate Documents submitted to client Client Approval/ Comments Functional requirements FEED Engineering documents for EPC call for tender Material Requisitions for LLI
  54. 54. ©2014-IFPTraining Training Agenda The Engineering work process • Getting started: Process design • Plant design • Engineering development phases • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  55. 55. ©2014-IFPTraining Interface with vendors Process simulations Equipment selection & purchase Foundation drawings Process data sheet Vendor data
  56. 56. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Instrumentation & Control design Fluids composition & conditions Material selection and specifications Civil design Structural steel design Electrical power generation & distribution Process Design
  57. 57. ©2014-IFPTraining Plant Design PFD, HMB Process Equipment sizing Utility consumption Utility Units Design Process Units Design Plant Layout Equipment mechanical design Equipment design by vendors P&IDs Piping Routing Instrumentation & Control design Fluids composition & conditions Material selection and specifications Civil design Structural steel design Electrical power generation & distribution
  58. 58. ©2014-IFPTraining Interface with vendors
  59. 59. ©2014-IFPTraining Interface with vendors Vendor Instrumentation & Control Electrical Layout Civil Piping Process
  60. 60. ©2014-IFPTraining Vendor data necessary for design development Vendor Instrumentation & Control Electrical Layout Civil P&ID Functional analysis C&E Terminals dwgs Power consumption General Arrangement Foundation drawing and loads, including auxiliaries! Piping Purchaser Mechanical connection list and dwg Process Utility consumption Battery limit conditions
  61. 61. ©2014-IFPTraining Plot Plan development with vendor information Example #1 – Combustion air blower FEED EPC - IFD EPC - IFC
  62. 62. ©2014-IFPTraining Plot Plan development with vendor information Example #2 – incinerator package FEED stage EPC Stage
  63. 63. ©2014-IFPTraining Training Agenda The Engineering work process • Engineering development phases • Getting started: Process design • Plant design • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequences for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  64. 64. ©2014-IFPTraining From sequential to concurrent Project execution ENGINEERING PROCUREMENT CONSTRUCTION Bill of materials Drawings
  65. 65. ©2014-IFPTraining ENGINEERING PROCUREMENT CONSTRUCTION From sequential to concurrent Project execution ENGINEERING PROCUREMENT CONSTRUCTION
  66. 66. ©2014-IFPTraining Training Agenda The Engineering work process • Engineering development phases • Getting started: Process design • Plant design • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  67. 67. ©2014-IFPTraining ENGINEERING PROCUREMENT From sequential to concurrent Project execution
  68. 68. ©2014-IFPTraining Piping installation work process Unit Plot Plan Line diagram
  69. 69. ©2014-IFPTraining Piping installation work process Piping LayoutLine diagram
  70. 70. ©2014-IFPTraining Piping installation work process Piping Layout 3D model
  71. 71. ©2014-IFPTraining Piping installation work process 3D model Isometric drawing
  72. 72. ©2014-IFPTraining Piping installation work process Plot Plan Line Diagram Piping Layout 3D model Isometric drawing
  73. 73. ©2014-IFPTraining Piping Material Management Above ground Piping Plot Plan Line Diagram Piping Layout 3D model Isometric drawing 1st PORFQ Final qties
  74. 74. ©2014-IFPTraining Management of MTOs Piping Material Material has to be ordered long time before Engineering is finalized Construction drawings are available e.g. First lot of Piping materials must be ordered month 9, construction drawings (isometric) will start being issued month 13 How to deal with this? Perform several MTOs: o 1st MTO: issued for Inquiry, to get the Unit prices o 2nd MTO: issued for Order o 3rd and subsequent MTOs: olrder balance between final and previously ordered quantities Order partial quantities initally, e.g., 70% of qties taken off to prime fab while avoiding ordering too much
  75. 75. ©2014-IFPTraining ENGINEERING CONSTRUCTION From sequential to concurrent Project execution QUANTITIES TO ERECT
  76. 76. ©2014-IFPTraining From sequential to concurrent Project execution
  77. 77. ©2014-IFPTraining From sequential to concurrent Project execution Engineering shall perform regular MTOs to provide Construction regular up-dates of total quantities to be installed for all commodities: m3 of concrete, tons of steel, meter or ton of UG piping, ton of AG piping, number of Electrical consumers, km of electrical cables, km of instrumentation cables.
  78. 78. ©2014-IFPTraining Training Agenda The Engineering work process • Engineering development phases • Getting started: Process design • Plant design • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequences for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  79. 79. ©2014-IFPTraining Piping activities
  80. 80. ©2014-IFPTraining Piping activities 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) PROJECT SCHEDULE MONTH 1 1 2 3 3 4 5 2 4 5 5
  81. 81. ©2014-IFPTraining Critical path of an Oil & Gas Project
  82. 82. ©2014-IFPTraining Critical path of an Oil & Gas Project
  83. 83. ©2014-IFPTraining Critical path of an Oil & Gas Project
  84. 84. ©2014-IFPTraining Critical path of an Oil & Gas Project
  85. 85. ©2014-IFPTraining Training Agenda The Engineering work process • Engineering development phases • Getting started: Process design • Plant design • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  86. 86. ©2014-IFPTraining Typical level 1 On-Shore EPC Project Engineering schedule
  87. 87. ©2014-IFPTraining Engineering progress measurement
  88. 88. ©2014-IFPTraining Engineering progress measurement Key Engineering Milestones for an EPC • P&ID 1st issue • LLI PO • HAZOP • 1st model review • 1st Piping PO • Control valves, PSVs PO • Plot Plan IFC • IFC P&IDs • 50% ISOs
  89. 89. ©2014-IFPTraining Engineering progress measurement Key Engineering Milestones for an EPC • P&ID 1st issue • LLI PO • HAZOP • 1st model review • 1st Piping PO • Control valves, PSVs PO • Plot Plan IFC • IFC P&IDs • 50% ISOs
  90. 90. ©2014-IFPTraining Engineering progress measurement
  91. 91. ©2014-IFPTraining Engineering progress measurement
  92. 92. ©2014-IFPTraining Training Agenda The Engineering work process • Engineering development phases • Getting started: Process design • Plant design • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  93. 93. ©2014-IFPTraining The “Ideal” Project Control dashboard Milestone status Milestone Planned Forecast Actual LLI PO PLaced 50% Eqt PO 1st steel PO 1st Piping PO IFC P&IDs IFC Plot Plan 50% Isometrics Quantities follow-up Commodity Initial Forecast Concrete (m3) Steel (tons) Piping (tons) Elec cables (km) Concrete workfront curve cumulative m3 of IFC dwgs Steel structure workfront curve cumulative tons of IFC dwgs Piping workfront curve Cumulative tons of IFC isos
  94. 94. ©2014-IFPTraining Training Agenda The Engineering work process • Engineering development phases • Getting started: Process design • Plant design • Interface with Vendors Project execution • From sequential to concurrent E/P/C • Consequence for Engineering: Bill of materials and quantities management What Engineering must do to meet the Project schedule How to control Engineering activities • The different progress measures • The ideal Control dashboard • The look-ahead
  95. 95. ©2014-IFPTraining The look ahead
  96. 96. ©2014-IFPTraining Beyond this presentation Did you enjoy this short introduction? Then join: IFP Training 3 day Engineering Management Training Nov 17th-19th, Paris All details and how to enroll at: http://www.ifptraining.com/course/engineering-management-1.html

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