©2

01

4 -

IFP

Tra

inin

g

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

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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?

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Process Design

Processs scheme selection

OilWell

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

©2

01

4 -

IFP

Tra

inin

g

Process Design

Processs scheme selection

HP Separator

LP Separator

Vapour

pressure

specP

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?

©2

01

4 -

IFP

Tra

inin

g

Process Flow Diagram + Heat & Mass Balance

©2

01

4 -

IFP

Tra

inin

g

Process Design / Sizing of Equipment

Tanker

HP Separator

LP Separator

©2

01

4 -

IFP

Tra

inin

g

Process Design

Equipment sizing

Sets the gas

cross section

Sets the liquid volume

Vessel size

©2

01

4 -

IFP

Tra

inin

g

Process Design

Equipment sizing

©2

01

4 -

IFP

Tra

inin

g

Process Design / Specification of Equipment

Tanker

HP Separator

LP Separator

©2

01

4 -

IFP

Tra

inin

g

Process Design / Specification of Equipment

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Plant Design

PFD,

HMB

Process Design

©2

01

4 -

IFP

Tra

inin

g

Plant Design

PFD,

HMB

Process

Equipment

sizing

Process Design

©2

01

4 -

IFP

Tra

inin

g

Plant Design

PFD,

HMB

Process

Equipment

sizing

Process Design Utility consumption

Utility Units Design

©2

01

4 -

IFP

Tra

inin

g

Plant Design

PFD,

HMB

Process

Equipment

sizing

Plant Layout

Process Design Utility consumption

Utility Units Design

©2

01

4 -

IFP

Tra

inin

g

Plant Design

©2

01

4 -

IFP

Tra

inin

g

Unit Plot Plan

©2

01

4 -

IFP

Tra

inin

g

Plant Design

PFD,

HMB

Process

Equipment

sizing

Utility consumption

Utility Units Design

Plant Layout

Fluids composition

& conditions

Material selection and

specifications

Process Design

©2

01

4 -

IFP

Tra

inin

g

Material Selection Diagram

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Equipment Mechanical Design

©2

01

4 -

IFP

Tra

inin

g

Equipment Mechanical Data Sheet

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Equipment General Arrangement

Process

Data Sheet

Waste

Heat

Boiler

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Civil Foundation Drawings

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Piping & Instrumentation Diagram

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

3D modelling

©2

01

4 -

IFP

Tra

inin

g

Piping isometric drawing

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Strucutral steel design

©2

01

4 -

IFP

Tra

inin

g

Strucutral steel design drawings

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Instrumentation design

©2

01

4 -

IFP

Tra

inin

g

Instrumentation list

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Electrical design

©2

01

4 -

IFP

Tra

inin

g

Electrical design

©2

01

4 -

IFP

Tra

inin

g

Electrical design

Turbogenerator

Switchgear

Transformer

©2

01

4 -

IFP

Tra

inin

g

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?

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

EngineeringDocuments 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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Interface with vendors

Process simulations

Equipment

selection &

purchase

Foundation

drawings

Process data

sheet

Vendor data

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Interface with vendors

©2

01

4 -

IFP

Tra

inin

g

Interface with vendors

Vendor

Instrumentation &

Control

Electrical

Layout

Civil

PipingProcess

©2

01

4 -

IFP

Tra

inin

g

Vendor data necessary for design development

VendorInstrumentation &

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

©2

01

4 -

IFP

Tra

inin

g

Plot Plan development with vendor information

Example #1 – Combustion air blower

FEED EPC - IFD EPC - IFC

©2

01

4 -

IFP

Tra

inin

g

Plot Plan development with vendor information

Example #2 – incinerator package

FEED stage EPC Stage

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

From sequential to concurrent Project execution

ENGINEERING

PROCUREMENT

CONSTRUCTION

Bill of

materials

Drawings

©2

01

4 -

IFP

Tra

inin

g

ENGINEERING

PROCUREMENT

CONSTRUCTION

From sequential to concurrent Project execution

ENGINEERING PROCUREMENT CONSTRUCTION

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

ENGINEERING

PROCUREMENT

From sequential to concurrent Project execution

©2

01

4 -

IFP

Tra

inin

g

Piping installation work process

Unit Plot Plan Line diagram

©2

01

4 -

IFP

Tra

inin

g

Piping installation work process

Piping LayoutLine diagram

©2

01

4 -

IFP

Tra

inin

g

Piping installation work process

Piping Layout 3D model

©2

01

4 -

IFP

Tra

inin

g

Piping installation work process

3D model Isometric drawing

©2

01

4 -

IFP

Tra

inin

g

Piping installation work process

Plot PlanLine

Diagram

Piping

Layout3D model

Isometric

drawing

©2

01

4 -

IFP

Tra

inin

g

Piping Material Management

Above ground Piping

Plot PlanLine

Diagram

Piping

Layout3D model

Isometric

drawing

1st PORFQ Final

qties

©2

01

4 -

IFP

Tra

inin

g

Management of MTOs

Piping MaterialMaterial 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, constructiondrawings (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 fabwhile avoiding ordering too much

©2

01

4 -

IFP

Tra

inin

g

ENGINEERING

CONSTRUCTION

From sequential to concurrent Project execution

QUANTITIES TO ERECT

©2

01

4 -

IFP

Tra

inin

g

From sequential to concurrent Project execution

©2

01

4 -

IFP

Tra

inin

g

From sequential to concurrent Project execution

Engineering shall perform regular MTOs to provide Constructionregular up-dates of total quantities to be installed for allcommodities:

� 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.

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Piping activities

©2

01

4 -

IFP

Tra

inin

g

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 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

1

1

23

3

4

5

2 4 5

5

©2

01

4 -

IFP

Tra

inin

g

Critical path of an Oil & Gas Project

©2

01

4 -

IFP

Tra

inin

g

Critical path of an Oil & Gas Project

©2

01

4 -

IFP

Tra

inin

g

Critical path of an Oil & Gas Project

©2

01

4 -

IFP

Tra

inin

g

Critical path of an Oil & Gas Project

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Typical level 1 On-Shore EPC Project Engineering schedule

©2

01

4 -

IFP

Tra

inin

g

Engineering progress measurement

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

Engineering progress measurement

©2

01

4 -

IFP

Tra

inin

g

Engineering progress measurement

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

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

©2

01

4 -

IFP

Tra

inin

g

The look ahead

©2

01

4 -

IFP

Tra

inin

g

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