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Engineering Management Training
HERVE BARON
Welcome to this presentation This is a preview of my Engineering Management training
3 public sessions will be held in 2015: May 26-28, Paris, France
September 2-4, Paris, France
October 23-26, Lombok (Bali area), Indonesia
© 2014 – Hervé Baron
HERVE BARON
Training objectives & scope
To get familiar with both BASIC and DETAILED Engineering To know the work of the various Engineering disciplines and get familiar with all common engineering deliverables To understand the challenges faced by Engineering To provide you with practical tips on how to control engineering execution by a sub-contractor
© 2014 – Hervé Baron
HERVE BARON
Training contents
In each Engineering discipline: Explain the design basis and criteria Clarify the technical vocabulary Provide basic technical knowledge Explain the discipline activities Show the disciplines deliverables Explain the sequence of the work with easy to read flow diagrams Highlight the interfaces with other disciplines
Confirm knowledge acquisition by a Quiz in the end
© 2014 – Hervé Baron
Perform hand-on exercise, in particular sizing
HERVE BARON
Textbook, 270 pages
Your training materials Exercise book, 60 pages
http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html
© 2014 – Hervé Baron
CD Training slides (~1000 nos) Great for your tablets!
HERVE BARON
My pedagogy
A word about my pedagogy…
All matters are explained by means of example. That’s the best way to learn!
I ask first before I present anything
You will be asked to find out by yourselves
The purpose is to make the brain wiring for the future © 2014 – Hervé Baron
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
Training Agenda Day 2
HERVE BARON
Hands-on – mini EPC Project
Key aspects of Engineering • • • • • • •
The Technical baseline: the Contractual requirements Engineering organization, split of Work and resources Interfaces between disciplines BASIC vs DETAIL design Document control Engineering Interface with Procurement, Construction, Third Parties IT
• Management of changes © 2014 – Hervé Baron
Training Agenda Day 3
HERVE BARON
The main challenge: meeting the Project schedule • FEED • EPC
How to control a Contractor The plan Progress measurement Factors that could Impact progress Engineering Controls and KPIs Engineering Quality Critical Points to watch
© 2014 – Hervé Baron
• • • • • •
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
Project development phases Front-end Loading
HERVE BARON
gate
gate
FEL-2 BASIC Engineering/Conceptual
FEL-3 FEED
Objective: Define the business opportunity
Objective: Confirm feasibility,, select technology, refine cost estimate, identify risks
Objective: refine cost estimate, prepare EPC phase
Content: Technical assessment, milestone schedule, estimated cost range
Content: Evaluate alternates, confirm feasibility, develop process design
Content: Evaluate alternates, confirm feasibility, develop process design
Deliverables: Functional requirements, economic evaluation
Deliverables: +/-30% cost estimate, preliminary schedule, layout, process design
Deliverables: +/-10-20% cost estimate, Design basis for EPC, MR for LLI
By: Company
By: Contractor
By: Contractor
© 2014 – Hervé Baron
FEL-1 Business Planning Phase
Basic Engineering/FEED
HERVE BARON
Client Documents submitted to client
Process Design Package (PDP)
Approval/ Comments
Engineering
Vendors / SubContractors Inquiries
Cost Estimate Department Documents for Inquiry: Bill of Materials / specifications Client Engineering basis for EPC call for tender ???
© 2014 – Hervé Baron
???
What else is delivered at FEED stage?
Quotations
The Engineering Work process synoptic
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Process design PFDs
P&IDs
H&M balance
Piping Instrumentation
Process data sheet
Equipment specification
Layout Civil Electrical
© 2014 – Hervé Baron
Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.
Vendor drawings
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
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List of common Engineering Deliverables
© 2014 – Hervé Baron
Specifications
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What difference can you see between the 2 sets of specifications? Design criteria for civil, structural and building engineering
Technical specification – structural steel materials and fabrication
Design specification for roads
Specification for asphalt paving
Design specification for sewage and drainage
Specification for hot dip galvanized anchor bolts
Specification for plant outdoor lighting
Technical specification Low Voltage Motors
Telecommunication and information system philosophy
Technical specification for Machine Monitoring system
Instrumentation and control system design basis
Technical specification for control valves
Fire Protection Design
Technical specification for fire detection devices in buildings
Safety concept Design philosophy for cathodic protection Specification for pipe supports design
Technical specification for wheeled fire extinguishers Technical specification for isolating joint Technical specification for cathodic protection materials
Technical specification for centrifugal pumps Technical specification for tail gas incinerator
© 2014 – Hervé Baron
Job specification for supply for piping sliding plates
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The (Basic) Engineering Design Data Draw the Table of Contents
© 2014 – Hervé Baron
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Simulations, Process Flow Diagrams, HMB, equipment list Process description Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2014 – Hervé Baron
• • • • • • • • • •
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• • • • •
Process design criteria
Design margins Design Pressure and Temperature criteria Equipment sizing criteria Line sizing criteria Control valve sizing criteria
© 2014 – Hervé Baron
Engineering disciplines: activities and deliverables
HERVE BARON
PROCESS Design basis and criteria Process Simulations, Process Flow Diagrams, HMB, equipment list Process description Equipment sizing P&IDs Piping specification and sizing Instrument process specification Process and Emergency shutdown Flare study Operating manual
© 2014 – Hervé Baron
• • • • • • • • • •
Process simulations
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Input - Feed composition and conditions
Simulator settings - Flow scheme - Thermodynamic model - Equipment performance
Output - Stream flows and composition - Equipment duty
© 2014 – Hervé Baron
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Block Flow Diagrams & Process Flow Diagrams
© 2014 – Hervé Baron
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The Process Flow Diagram (PFD)
Results from process simulations
Depicts the various Equipment within a Process (or Utility) Unit and their sequence
Shows the process controls
The individual drawing item of the PFD is the Equipment Item
© 2014 – Hervé Baron
HERVE BARON
Process eqiupment sizing Case study: Production separator Sets the gas cross section
Vessel size
Sets the liquid volume
© 2014 – Hervé Baron
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Process Data Sheet
© 2014 – Hervé Baron
Contents of the Process Data Sheet: • Design conditions • Overdesign • Fluid properties • Equipment duty • Skeleton drawing & dimensions • Material (generic type) and corrosion allowance • Specification of internals: demister, distributor, baffle etc. • Nozzles list • Allowable pressure drop, fouling factor, Cp, Cv, enthalpy curve (for HX, heaters) •Available NPSH (for pumps)
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Piping & Instrumentation Diagram (P&ID)
What purpose does a P&ID serve?
During operation: • Reference drawing for operator, work permit, plant modifications etc.
© 2014 – Hervé Baron
At design stage: • Defines the design basis for Piping & Instrumentation disciplines • Serves to show and agree the operating and maintenance features between Engineer and Owner or between Engineer and Vendor • Serves to show the interface with equipment/package vendors • Perform HAZOP review
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Piping & Instrumentation Diagrams (P&IDs)
Important features (1/3)
© 2014 – Hervé Baron
Normal operation • Redundancy for critical instruments / safety switches Shutdown • Check valves Start-up • Pressurization • warm-up / purge lines Maintenance • Equipment isolation & bypass: valves, spectacle/blind • Nitrogen injection, vent • Drains • Control and ON/OFF valves isolation • Instrument isolation
HERVE BARON Various
• • • • • • • •
Piping & Instrumentation Diagrams (P&IDs) types of P&IDs
Legend and Symbols Identification & Numbering Details and Typicals Process or Utility P&ID Distribution P&ID Interconnection P&ID Pumps auxiliary P&ID Package P&ID
P&ID representation
Details
© 2014 – Hervé Baron
P&ID work sequence
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Vendor drawings
P&ID Review
IFR
HAZOP
IFD Piping MTO & 1st PO
Piping MTO & Top-up’s
© 2014 – Hervé Baron
Piping MTO & RFQ
IFC
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Quiz Which revision of P&IDs has the following purpose/contents?
Purpose Collect Client comments Perform PID review Perform HAZOP Perform Piping MTO for 1st Piping purchase Freeze Control system I/O list Issue Piping ISOs Contents Comments from all disciplines
IFR
IFD
IFC
IFR
IFD
IFC
Comments from Piping, I&C disciplines Finalized interfaces with eqt/package Exercised Contract Option(s) © 2014 – Hervé Baron
Size, number of PSVs and CVs Diameter of process lines Diameter of utility lines HAZOP comments incorporated Client comments incorporated
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Process Engineering / schedule Hands-on exercise
© 2014 – Hervé Baron
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
HERVE BARON
Process Data Sheet vs Mechanical Data Sheet
© 2014 – Hervé Baron
Look at the PDS and MDS in your exercise book. What additional information is contained in the MDS? What does Mechanical design entail?
HERVE BARON
Equipment / Mechanical
What is a package ? What is, for Engineering, the purpose to order as a package ? What is usually ordered as a package ? Which is the responsible discipline ? Which document is produced to specify a package ? By whom ?
© 2014 – Hervé Baron
What are the key things to consider when specifying a package?
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Instrumentation Specification for packaged units
© 2014 – Hervé Baron
Test
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Identify the documents issued by Engineering to order each type of equipment… Equipment
Process discipline Equipment/Mechanical discipline PDS
Duty spec
MDS
Particular General Specification Specification
MR
Pressure Vessel Rotating equipment Reactor Heat Exchanger – Shell & Tube Heat Exchanger – Other type Package
© 2014 – Hervé Baron
Fired heater
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
HAZOP hands-on exercise
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Fill the table © 2014 – Hervé Baron
Quantitative Risk Analysis (QRA) case study: gas leak in Turbo-compressor building
HERVE BARON
Step 2: Event tree analysis Release Frequency
Probability of immediate ignition for 1-50 kg/s release rate is 7% (from statistical data)
Immediate ESD & Fire ignition Fighting
0,998 0,070
Delayed Ignition
Explosion/ Flash-fire
Consequence Event
Gas detectors are provided inside the building, that activate isolation and depressurization. assumed Jet fire ESD It& is FF that they operate 95% of the time.
0,002
Jet fire no ESD & FF
7,779E-03 1,520E-05
Probability of explosion vs flash fire (12%) depends on mass of gas and degree of confinement
1,11E-01 Release/yr 0,949
Dispersion
9,827E-02
0,120
Explosion
1,774E-05
0,880
Flash fire
1,301E-04
Dispersion
5,133E-03
0,930 0,028 0,051 0,972 Yes
?
5%
What is the frequency of an explosion?
© 2014 – Hervé Baron
Frequency (event/year) Jet fire ESD & FF 7,779E-03 Probability of delayed ignition (2.8%)Jet takes into account fire no ESD & FF 1,520E-05 equipment explosion protection (Ex) Explosion 1,774E-05 Flash Fire 1,301E-04 Dispersion 1,034E-01
No B04a/b/c/d
Frequency (ev/y)
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
Civil foundation calculation
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Overturning axis Input Loads: dead, operating, test, live, wind, seismic, Soil data: bearing capacity, angle of friction, unit weight, boyancy
Dimensions to test
• Stability check for sliding and overturning • Bearing pressure check
De-stabilizing moment
Stabilizing moment
© 2014 – Hervé Baron
Safety factors (for sliding and overturning)
Calculation
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Foundation guide drawing
© 2014 – Hervé Baron
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Pipe-rack design
What is usually the governing load? What is the governing design criteria?
© 2014 – Hervé Baron
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
Layout/principles
HERVE BARON
Define the respective position of the 6 items as per good plant layout practice
…
PREVAILING WIND
…
…
… 1
3
… 6
5
© 2014 – Hervé Baron
4 2
…
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On-shore plant: Equipment spacing recommendations as per GE GAP Guidelines 2.5.2
© 2014 – Hervé Baron
HERVE BARON
Layout principles: typical Unit Layout
© 2014 – Hervé Baron
Piping installation
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Line diagram
© 2014 – Hervé Baron
Unit Plot Plan
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Piping design iso vs Shop iso
© 2014 – Hervé Baron
Piping installation work process
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Plot Plan
Piping line diagram
Piping studies & layout
Piping 3D modelling
Piping isometric drawing
Stress OK?
?
Piping isometric drawing IFC
Piping stress analysis
By whom? For which lines?
© 2014 – Hervé Baron
For some lines, another check is done.
Piping material management work process
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PFD Plot Plan Process eqt list
Piping line diagram
Piping studies & layout
1st Piping MTO: for Inquiry
Stress OK?
Piping isometric drawing IFC
? IFD P&IDs
?
IFC P&IDs
?
At which project month shall the steps take place?
3rd and next Piping MTOs © 2014 – Hervé Baron
?
Piping isometric drawing
2nd Piping MTO, for Order
? IFR P&IDs
Piping 3D modelling
HERVE BARON
Quiz
Put the following tasks in order
Perform piping Material-Take-Off for first purchase
HAZOP
P&ID review between COMPANY and CONTRACTOR
Issue of IFR P&ID
P&ID IFC issue
Issue of IFD P&ID © 2014 – Hervé Baron
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
HERVE BARON
Process Control System
Case of Package controlled by Central Process Control System
© 2014 – Hervé Baron
What documents from the package Vendor are needed by the DCS Vendor in this case?
Training Agenda Day 1
HERVE BARON
Engineering in the Project: Role, Organization, Documents, Generalities
General documents, Design basis and design criteria
The engineering disciplines PROCESS MECHANICAL SAFETY & ENVIRONMENT CIVIL PLANT LAYOUT & PIPING INSTRUMENTATION ELECTRICAL
© 2014 – Hervé Baron
• • • • • • •
HERVE BARON
Electrical consumer list
© 2014 – Hervé Baron
HERVE BARON
Electrical Engineering
© 2014 – Hervé Baron
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Training Agenda Day 2
Hands-on – mini EPC Project
© 2014 – Hervé Baron
HERVE BARON
Hands-on – mini EPC Project
© 2014 – Hervé Baron
Training Agenda Day 2
HERVE BARON
Hands-on – mini EPC Project
Key aspects of Engineering • • • • • • •
The Technical baseline: the Contractual requirements Engineering organization, split of Work and resources Interfaces between disciplines BASIC vs DETAIL design Document control Engineering Interface with Procurement, Construction, Third Parties IT
• Management of changes © 2014 – Hervé Baron
HERVE BARON
1.
CONTRACTOR identifies, in the course of the design, that the capacity of one utility unit foreseen in the DESIGN PACKAGE is not enough. A unit with increased capacity is required. A document part of the exclusions listed in the Endorsement Certificate specifies that Sea Water used for cooling should be discharged no more with no more than 10°C temperature increase. COMPANY now asks for 3°C. This required CTR to put additional cooling facilities.
Discuss CTR’s entitlement to a CHANGE ORDER in each case?
© 2014 – Hervé Baron
2.
ENDORSEMENT: case study
61
Training Agenda Day 2
HERVE BARON
Hands-on – mini EPC Project
Key aspects of Engineering • • • • • • •
The Technical baseline: the Contractual requirements Engineering organization, split of Work and resources Interfaces between disciplines BASIC vs DETAIL design Document control Engineering Interface with Procurement, Construction, Third Parties IT
• Management of changes © 2014 – Hervé Baron
Engineering Split of work
HERVE BARON
What is the typical share of manhours done in home office versus low cost center?
Discipline
Paris (%)
India (%)
Process/HSE Design Equipment Electrical Civil Piping
© 2014 – Hervé Baron
Instrumentation
HERVE BARON
Engineering Split of work/Piping Horizontal split
© 2014 – Hervé Baron
Training Agenda Day 2
HERVE BARON
Hands-on – mini EPC Project
Key aspects of Engineering • • • • • • •
The Technical baseline: the Contractual requirements Engineering organization, split of Work and resources Interfaces between disciplines BASIC vs DETAIL design Document control Engineering Interface with Procurement, Construction, Third Parties IT
• Management of changes © 2014 – Hervé Baron
HERVE BARON
The Engineering work sequence Fill the missing captions
© 2014 – Hervé Baron
Training Agenda Day 2
HERVE BARON
Hands-on – mini EPC Project
Key aspects of Engineering • • • • • • •
The Technical baseline: the Contractual requirements Engineering organization, split of Work and resources Interfaces between disciplines BASIC vs DETAIL design Document control Engineering Interface with Procurement, Construction, Third Parties IT
• Management of changes © 2014 – Hervé Baron
HERVE BARON
BASIC vs DETAIL design
© 2014 – Hervé Baron
Training Agenda Day 2
HERVE BARON
Hands-on – mini EPC Project
Key aspects of Engineering • • • • • • • •
The Technical baseline: the Contractual requirements Engineering organization, split of Work and resources Interfaces between disciplines BASIC vs DETAIL design Document control Engineering Interface with Procurement, Construction, Third Parties IT Management of changes © 2014 – Hervé Baron
Origin of changes
HERVE BARON
Identify the likely impact of the Engineering reviews on the design Plot Plan
P&IDs Design Blast ESD criteria resistance logic
New New New valves instruments accesses
HAZID HAZOP QRA
© 2014 – Hervé Baron
P&ID review 3D model review SIL review
Training Agenda Day 3
HERVE BARON
The main challenge: meeting the Project schedule • FEED • EPC
How to control a Contractor The plan Progress measurement Factors that could Impact progress Engineering Controls and KPIs Engineering Quality Critical Points to watch
© 2014 – Hervé Baron
• • • • • •
Key Engineering Milestones for an EPC
HERVE BARON
At which time (Project Month) must the following be issued/done to support the Project execution? • • • • • • •
P&ID 1st issue LLI Material Requisition Issued for Purchase HAZOP Control valves, PSVs PO issue of Plot Plan IFC issue of IFC P&Ids 50% ISOs issued © 2014 – Hervé Baron
HERVE BARON
Typical level 1 On-Shore EPC Project Engineering schedule
© 2014 – Hervé Baron
Training Agenda Day 3
HERVE BARON
The main challenge: meeting the Project schedule • FEED • EPC
How to control a Contractor The plan Progress measurement Factors that could Impact progress Engineering Controls and KPIs Engineering Quality Critical Points to watch
© 2014 – Hervé Baron
• • • • • •
HERVE BARON
Safety Engineering
© 2014 – Hervé Baron
In your opinion, how is Safety performing?
Training Agenda Day 3
HERVE BARON
The main challenge: meeting the Project schedule • FEED • EPC
How to control a Contractor The plan Progress measurement Factors that could Impact progress Engineering Controls and KPIs Engineering Quality Critical Points to watch
© 2014 – Hervé Baron
• • • • • •
HERVE BARON
Engineering progress KPIs
© 2014 – Hervé Baron
HERVE BARON
EPC Key Engineering Milestones and benchmarks
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 Primary steel MTO Primary steel drawings IFC
Additional Milestones for Off-Shore jobs © 2014 – Hervé Baron
• • • • • • • • • • •
Engineering Manhours benchmarks
HERVE BARON
FEED: number of Home Office (H.O.) manhours per equipment item • ??? hours
EPC: number of H.O. manhours per equipment item • ??? hours
EPC: number of H.O. manhours per USD of CAPEX? • ??? hour / mln USD
EPC: number of Procurement (Buyer, Expediter, Inspector, Transit) manhours for one Purchase Order?
Please guess…
© 2014 – Hervé Baron
• ???? manhours
Engineering Management Training
HERVE BARON
Your instructor: Hervé Baron, Project Manager Professional experience/positions held •
Process Engineer (2 years), Production Engineer (2 years)
•
Engineering Manager (4 years) for EPC On-Shore 300mln USD Project
•
Field Engineering Manager (4 years) for EPC Off-shore (FPSO) 1bln USD Project
•
Project Manager (2 years) for 50mln USD EPC revamping
•
Project Manager (1 year) for FEED and Basic Design
•
Project Control Manager (1 year) for 100,000 manhours FEED
•
Contract Manager (3 years) for 700mln USD and 1bln USD EPC
Professional experience/Companies worked with
Developer and instructor of IFP Training’s
•
TOTAL, for 4 years
•
Engineering Management Training (10 sessions held),
•
SAIPEM, for 8 years
•
Project control training (6 sessions held),
•
TECHNIP, for 6 years
© 2014 – Hervé Baron
Training experience
2015 Training schedule
HERVE BARON
3 training sessions will be held in 2015:
Paris: May 26-28, September 2-4
For details and to enroll please go to:
http://www.ifptraining.com/course/engineering-management-5219.html
Lombok (near Bali), Indonesia: Oct 20-23
For details and to enroll please go to: http://rhenindo.com/trainings/barons-oil-and-gas-engineering-management/
© 2014 – Hervé Baron
Pick the location you like!
