The execution of a
HERVE
HERVE
BARON
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Complex Project…
A guided tour
© 2013 – Hervé Baron
HERVE
BARON
The actors The suppliers
The
COMPANY
The EPC
“Client”
Contractor
© 2013 – Hervé Baron
The sub-contractors
HERVE
BARON The phases
Sanction Sanction
Conceptual evaluation
© 2013 – Hervé Baron
Basic Engineering Project Execution
+ Pre-Project
By ENGINEERING by EPC CONTRACTOR
By COMPANY
HERVE
BARON
Design Procurement Manufacturing Shipping
Construction Inspection &
Installation Hand-over
& erection tests
© 2013 – Hervé Baron
HERVE
BARON The multiple sides of a Project
Project Control
PROJECT
Human Resources Management
© 2013 – Hervé Baron
HERVE
BARON
The multiple sites of a Project
Engineering Sub-Contractor
Home office (Paris) (India)
•Project management
•Detail Engineering (part) Detail Engineering (part)
•Procurement
Shipyard (Korea)
Hull Engineering & Fabrication
Satellite office
Detail Engineering (part)
Fabrication yard (Nigeria):
Fabrication (part)
© 2013 – Hervé Baron
Offshore (Nigeria):
Installation, commissioning, start-up
Shipyards (Singapore &
Malaysia)
Topsides Fabrication & Integration
HERVE
BARON
Project
Engineering Procurement Construction
© 2013 – Hervé Baron
HERVE
BARON
Project
Engineering Procurement Construction
© 2013 – Hervé Baron
HERVE The facilities design basis
BARON
Process facilities: Infrastructure:
50
Administrative and technical
Pressure (bar)
Feedstock and products flow 45 buildings
Feedstock composition 40
Control room
Battery limit conditions 35
30
Access road
Equipment Spare
25 Site fencing, gates, check point
20
Performance: 15
Design criteria:
Products specifications 10
% of over design
5
Energy efficiency, emissions
0
-85 -80 -75 -70 -65 -60 -55
Environment data:
Utilities:
Min/max temperature
Electric power supply
Rain/snow fall
Other utilities
Wind
Geological conditions
Systems:
© 2013 – Hervé Baron
Process control
Applicable codes and standards:
Fire/gas alarm
International standards
Public address, LAN, PABX
Local rules
HERVE Engineering
BARON
in the Project
Design basis: Documents for Construction:
- Functional Construction drawings &
requirements specifications
Engineering
- Client Documents for Purchase:
specifications
bill of quantity & specification
- Design codes
© 2013 – Hervé Baron
HERVE
BARON
Project
Engineering Procurement Construction
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping
© 2013 – Hervé Baron
HERVE
BARON
Project
Engineering Procurement Construction
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping
© 2013 – Hervé Baron
HERVE Process simulations
BARON
© 2013 – Hervé Baron
HERVE
BARON
Thermodynamic Heat & Material
calculations balance
© 2013 – Hervé Baron
Process Flow
Diagram (PFD)
HERVE
BARON Equipment list
© 2013 – Hervé Baron
HERVE
BARON
Equipment
duty
© 2013 – Hervé Baron
HERVE
BARON
Process data sheet
© 2013 – Hervé Baron
HERVE
BARON Process Flow Diagram (PFD)
© 2013 – Hervé Baron
HERVE
BARON
Piping & Instrumentation Diagram (P&ID)
© 2013 – Hervé Baron
HERVE
BARON
Piping &
© 2013 – Hervé Baron
Instrumentation
Diagram (P&ID)
HERVE
BARON
Process control
© 2013 – Hervé Baron
HERVE
BARON Emergency shut down
© 2013 – Hervé Baron
HERVE
BARON Emergency relief
© 2013 – Hervé Baron
HERVE
BARON Operating manual
© 2013 – Hervé Baron
HERVE
BARON
Project
Engineering Procurement Construction
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping
© 2013 – Hervé Baron
HERVE
BARON
Rotating machinery
© 2013 – Hervé Baron
HERVE
BARON Pressure vessels
© 2013 – Hervé Baron
HERVE
BARON
Heat exchangers
© 2013 – Hervé Baron
HERVE
BARON
Packages,
Fired Equipment
© 2013 – Hervé Baron
HERVE
BARON
Process data
sheet
Mechanical
data sheet
© 2013 – Hervé Baron
HERVE
BARON Material Requisition
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
Project
Engineering Procurement Construction
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE Fire fighting
BARON
© 2013 – Hervé Baron
HERVE
BARON Passive fire protection
© 2013 – Hervé Baron
HERVE
BARON
Fire & Gas detection layout
© 2013 – Hervé Baron
HERVE Environmental Impact Assessment
BARON
© 2013 – Hervé Baron
HERVE
BARON
Project
Engineering Procurement Construction
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
BARON © 2013 – Hervé Baron
HERVE
BARON © 2013 – Hervé Baron
HERVE
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
© 2013 – Hervé Baron
Equipment supporting
structures
HERVE
BARON
© 2013 – Hervé Baron
Piping supporting
structures (pipe-racks)
HERVE
BARON
© 2013 – Hervé Baron
Structural design
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
Structural
© 2013 – Hervé Baron
drawings
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
Architectural drawings
© 2013 – Hervé Baron
Equipment layout
drawing
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
Project
Engineering Procurement Construction
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
Layout/
principles
© 2013 – Hervé Baron
HERVE
BARON
Layout/consideration for all networks
© 2013 – Hervé Baron
HERVE
BARON General Plot Plan
© 2013 – Hervé Baron
HERVE
BARON
Piping Layout
drawing
© 2013 – Hervé Baron
HERVE
BARON 3D modelling
© 2013 – Hervé Baron
HERVE
BARON
3D model clash check
3D model review
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON Piping Design
ANSI B31.8 (for gas pipelines and
compressor stations)
© 2013 – Hervé Baron
HERVE
BARON Piping Design
ANSI B31.8 (for gas pipelines and
compressor stations)
© 2013 – Hervé Baron
HERVE
BARON Thickness (mm) Number of passes
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
BARON © 2013 – Hervé Baron
HERVE
BARON © 2013 – Hervé Baron
HERVE
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
Isometric drawing
© 2013 – Hervé Baron
HERVE
Piping Pre-fabrication
BARON
© 2013 – Hervé Baron
HERVE
BARON
Piping General
Arrangement drawing
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON Standard Pipe Support
drawings
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
Material Selection
© 2013 – Hervé Baron
HERVE
BARON Material Specification
© 2013 – Hervé Baron
HERVE
BARON Material Specification
© 2013 – Hervé Baron
HERVE
BARON
Project
Engineering Procurement Construction
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE Instrument data sheet
BARON
© 2013 – Hervé Baron
HERVE
BARON
© 2013 – Hervé Baron
Process Control System
HERVE System architecture
BARON
drawing
© 2013 – Hervé Baron
HERVE Mechanical Equipment Control
BARON
© 2013 – Hervé Baron
HERVE The instrumentation hardware
BARON Instrument room Control room
Marshalling Controller
cabinet cabinet
VDU
PT JB
Process
line CPU
LAN
Secondary cable
Multi cable
© 2013 – Hervé Baron
HERVE
BARON
© 2013 – Hervé Baron
Building detail drawing/
Telecom and PAGA layout
HERVE Cable routing drawings
BARON
© 2013 – Hervé Baron
Cable list
HERVE
BARON
© 2013 – Hervé Baron
Cable routing inside
technical room
HERVE
BARON
Project
Engineering Procurement Construction
Instruments& Layout
Process Electrical Equipment Civil Safety
Control & Piping
© 2013 – Hervé Baron
HERVE
BARON
© 2013 – Hervé Baron
Electrical consumer list
HERVE
BARON
Electrical Load
Summary
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON
General One
Line Diagram
© 2013 – Hervé Baron
HERVE
BARON
Generators
Single line diagram
Switchgear
Transformer
© 2013 – Hervé Baron
HERVE
BARON Electrical equipment layout
© 2013 – Hervé Baron
HERVE
BARON
Electrical
Control System
© 2013 – Hervé Baron
HERVE
BARON
Process design
PFDs
H&M balance
© 2013 – Hervé Baron
HERVE
BARON
Process design
PFDs
H&M balance
Equipment specification
Process
data sheet
Rotating
Pressure vessels
© 2013 – Hervé Baron
Fired equipment
Heat exchangers
Packages etc.
HERVE
BARON
Process design
PFDs P&IDs
H&M balance
© 2013 – Hervé Baron
HERVE
BARON
Process design
PFDs P&IDs
H&M balance
Piping
Instrumentation
Equipment specification
Process
data sheet Vendor
Rotating drawings Layout
Pressure vessels
Civil
© 2013 – Hervé Baron
Fired equipment
Heat exchangers
Electrical
Packages etc.
HERVE
BARON
Process design
PFDs P&IDs
H&M balance
Piping
Instrumentation
Equipment specification
Process
data sheet Vendor
Rotating drawings Layout
Pressure vessels
Civil
© 2013 – Hervé Baron
Fired equipment
Heat exchangers
Electrical
Packages etc.
HERVE Electrical
BARON
Layout Instrumentation &
Vendor Control
Piping
Process
Civil
© 2013 – Hervé Baron
HERVE
BARON
What the
Vendor
supplied
What
Engineering
designed
© 2013 – Hervé Baron
HERVE Field Engineering
BARON
© 2013 – Hervé Baron
HERVE Interested and wanting to know more on Engineering?
BARON
© 2013 – Hervé Baron
A unique synthesis for the busy Project professional
200 pages, 250 illustrations
HERVE
BARON
Project
Engineering Procurement Construction
© 2013 – Hervé Baron
HERVE
BARON Procurement
© 2013 – Hervé Baron
HERVE
BARON Procurement / Steps
Inquiry (Call for Tender)
Short listing
Bid analysis
Clarifications
Negotiations
Purchase Order
Expediting
Inspection
© 2013 – Hervé Baron
Delivery
Warranty Period
HERVE
BARON Procurement / Supplier selection criteria
Technical Compliance
Price
Qualification of supplier
Schedule
Load of workshop
References
References with final Client
Financial situation
© 2013 – Hervé Baron
Annual turn-over
Internal feed-back
HERVE
BARON Procurement
© 2013 – Hervé Baron
HERVE
BARON Expediting
© 2013 – Hervé Baron
HERVE
BARON Expediting
© 2013 – Hervé Baron
HERVE
BARON Inspection
© 2013 – Hervé Baron
HERVE
BARON Inspection
© 2013 – Hervé Baron
Shipping
BARON © 2013 – Hervé Baron
HERVE
Shipping
BARON © 2013 – Hervé Baron
HERVE
© 2013 – Hervé Baron
Shipping
BARON
HERVE
HERVE
BARON
Project
Engineering Procurement Construction
© 2013 – Hervé Baron
HERVE
BARON Earthworks
© 2013 – Hervé Baron
Pipeline
BARON © 2013 – Hervé Baron
HERVE
Pipeline
BARON © 2013 – Hervé Baron
HERVE
Roads
BARON © 2013 – Hervé Baron
HERVE
© 2013 – Hervé Baron
Buildings
BARON
HERVE
HERVE
BARON Civil Works
Sand
Aggregate
Cement
Admixtures
© 2013 – Hervé Baron
HERVE
BARON Civil Works
© 2013 – Hervé Baron
HERVE
BARON Civil Works
© 2013 – Hervé Baron
HERVE
BARON Civil Works
© 2013 – Hervé Baron
HERVE
BARON Civil Works
© 2013 – Hervé Baron
HERVE
BARON Civil Works
© 2013 – Hervé Baron
HERVE
BARON Pre-fabrication
© 2013 – Hervé Baron
Erection
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON Underground networks
© 2013 – Hervé Baron
HERVE
BARON Plant erection
© 2013 – Hervé Baron
HERVE
BARON Steel structure erection
© 2013 – Hervé Baron
HERVE
BARON Equipment installation
© 2013 – Hervé Baron
HERVE
BARON Equipment installation
© 2013 – Hervé Baron
HERVE
BARON Piping Pre-fabrication
© 2013 – Hervé Baron
HERVE
BARON Piping erection
© 2013 – Hervé Baron
HERVE
BARON Piping erection
© 2013 – Hervé Baron
HERVE
BARON Field Instrumentation Installation
© 2013 – Hervé Baron
HERVE
BARON Electrical equipment connection
© 2013 – Hervé Baron
HERVE
BARON Cable pulling
© 2013 – Hervé Baron
HERVE
BARON Arrangement of Technical rooms
© 2013 – Hervé Baron
HERVE
BARON Cable connections
© 2013 – Hervé Baron
HERVE
BARON Other Systems Field Equipment Installation
© 2013 – Hervé Baron
HERVE
BARON Control room consoles installation
© 2013 – Hervé Baron
Testing
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON Commissioning
Handover System
Sub-System
Document Folder
Circuit Elect Equip Mech Equip
Instrument
Loop
Junction Instrument Instrument
Box Cable Tag
© 2013 – Hervé Baron
HERVE
BARON The multiple sides of a Project
Project Control
PROJECT
Human Resources Management
© 2013 – Hervé Baron
HERVE
BARON Project Organisation
Project
Manager
Engineering Procurement Project Control
Site Manager
Manager Manager Manager
Project Discipline Construction Contract Scheduling
Purchasers Expediters Inspectors Cost Control
Engineers Engineers Manager Manager Manager
Construction
Process
Superintendent
Construction
Civil
supervisor
Construction
Instrumentation
superintendent
Construction
Electrical
supervisor
© 2013 – Hervé Baron
Equipment
HERVE
BARON Project procedures
© 2013 – Hervé Baron
HERVE
BARON Project temporary facilities
© 2013 – Hervé Baron
HERVE
BARON Project temporary facilities
© 2013 – Hervé Baron
HERVE
BARON Project temporary facilities
© 2013 – Hervé Baron
HERVE
BARON Project temporary facilities
© 2013 – Hervé Baron
HERVE
BARON Project temporary facilities
© 2013 – Hervé Baron
HERVE
BARON Construction Procedures
© 2013 – Hervé Baron
BARON © 2013 – Hervé Baron
HERVE
HERVE
BARON Quality Control
© 2013 – Hervé Baron
HERVE
BARON Quality Control
Temperature
Sampling
Slump
© 2013 – Hervé Baron
HERVE
BARON Quality Control
© 2013 – Hervé Baron
HERVE
BARON Cost Control
© 2013 – Hervé Baron
© 2013 – Hervé Baron
Insurance
BARON
HERVE
HERVE
BARON Contracts
P.O.
P.O.
Purchase
Orders P.O.
EPC
Sub-Contracts
Main Contract Sub
© 2013 – Hervé Baron
Sub
HERVE
BARON Contracts
Terms and
Conditions
Price
Schedule
Performance
guarantees
EPC
Technical
Main Contract
basis
Specifications,
codes & stds
© 2013 – Hervé Baron
HERVE
BARON Contracts
© 2013 – Hervé Baron
HERVE
BARON Contracts
E P
© 2013 – Hervé Baron
HERVE
BARON Contracts
E P C
© 2013 – Hervé Baron
HERVE
BARON Contracts
© 2013 – Hervé Baron
∑ + x%
HERVE
BARON Construction contracts
Civil
© 2013 – Hervé Baron
HERVE
BARON Construction contracts
Mechanical
© 2013 – Hervé Baron
HERVE
BARON Construction contracts
E&I
© 2013 – Hervé Baron
HERVE
BARON Construction contracts
General
Contractor
© 2013 – Hervé Baron
HERVE Contracts
BARON
Terms and Conditions
EPC
Main Contract
Obligations of the 2 parties
© 2013 – Hervé Baron
Limit of liability
Penalties in case of bad performance
Conflict resolution
HERVE
BARON Quality Assurance (QA)
© 2013 – Hervé Baron
HERVE
BARON Quality Assurance (QA)
© 2013 – Hervé Baron
HERVE
BARON Quality Assurance (QA)
Email
Email vs Technical Query…
© 2013 – Hervé Baron
HERVE
BARON Quality Assurance (QA)
Email
Unformal/Unrecoverable!
Email vs Technical Query…
Formal/Recoverable!
© 2013 – Hervé Baron
HERVE
BARON Quality Assurance (QA)
Email
Unformal/Unrecoverable!
Email vs Technical Query…
Formal/Recoverable!
© 2013 – Hervé Baron
Think of somebody trying to find out
what was CPY decision in 3 years time...
HERVE
BARON Quality Assurance (QA)
© 2013 – Hervé Baron
HERVE
BARON Document Control
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
Discipline code
A Instrumentation & Control
C Civil engineering
E Electrical
G Project general documents
J Mechanical
K Safety
© 2013 – Hervé Baron
M Piping & Layout
P Processes
S Steel Structures
V Vessels – Heat exchangers
W Materials – Welding
HERVE
BARON Document Control
© 2013 – Hervé Baron
HERVE
BARON Document Control
Client
Documents Approval/
submitted
to client Comments
Engineering
Documents
Comments
© 2013 – Hervé Baron
submission
Vendors
HERVE
BARON Electronic Document Management System
Center 1 Sr.
Mgmt Center 2 Sr. Correspondence
Intranet / Mgmt
etc.
Internet
Electronic Document
Management System
Breakdown Projects
structures
Engineering
Reports
documents
Interfaces
© 2013 – Hervé Baron
Intranet /
Internet
Vendor
Satellite
documents
Engineering Construction
Center Site
HERVE
BARON Interface Management
© 2013 – Hervé Baron
HERVE
BARON Scheduling
MONTH
PROJECT SCHEDULE
PLANT START-UP
5
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
PIPING PRE-FABRICATION & INSTALLATION
PIPING MATERIAL & DRAWINGS AT SITE 4 X X X X X X X X X X
PIPING MATERIAL MANUFACTURING & SHIPPING X X X X X X
PURCHASE OF PIPING MATERIAL
2 3
TECHNICAL & COMMERCIAL CLARIFICATIONS X X
CALL FOR TENDER FOR PIPING MATERIAL
PREPARE PIPING MATERIAL TAKE-OFF X
PIPING ROUTING STUDIES 1 X X X
PIPING & INSTRUMENTATION DIAGRAMS (PIDs)
1 3 5
4 5
2
© 2013 – Hervé Baron
HERVE
BARON Scheduling
© 2013 – Hervé Baron
HERVE
BARON Progress Monitoring
How would you measure
progress?
© 2013 – Hervé Baron
HERVE
BARON Progress Monitoring
© 2013 – Hervé Baron
HERVE
BARON Progress Monitoring
© 2013 – Hervé Baron
HERVE
BARON Progress Monitoring
© 2013 – Hervé Baron
HERVE
BARON IT
Today: 3D
Tomorrow:
15 years ago: 2D
3D & data
© 2013 – Hervé Baron
© 2013 – Hervé Baron
IT
BARON
HERVE
© 2013 – Hervé Baron
Safety
BARON
HERVE
HERVE
BARON
Safety
Guard Rail System with Toe Planking
Boards
Runner
Bearer
Cross Bracing Post
© 2013 – Hervé Baron
Sill Longitudinal Brace
© 2013 – Hervé Baron
Safety
BARON
HERVE
HERVE
BARON
Human resources / career path
Graduate Engineer, 25 years old
Process Engineer 3-5 yrs
Project Engineer 5 yrs
Engineering Manager/ 5-7 yrs
Deputy Project Manager
Project Manager
40-45 yrs old
© 2013 – Hervé Baron
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!
HERVE Beyond this presentation…
BARON
Share my new developments
Find my other on-line and classroom training
[Link]
© 2013 – Hervé Baron