HERVE BARON
Oil & Gas Engineering Training
HERVE BARON
Dear colleague, I am glad to share with your this educative material on the Engineering of Oil & Gas facilities. I dev develop eloped ed it for clas classr sroo oom m trai traini ning ng se sess ssio ions ns wh whic ich h I have have been been conducting since 200. !his material will give you an overview of the wor" and deliverables of the different engineering disciplines. I also thrived to produce wor"flow visuals to help understand the wor" se#uence of each eac h discipline and how they interface. interface. I wish you an en$oyable $ourney within Engineering%
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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality
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Do you think that HSE is only for HSE professionals?
Do you think you cannot do your bit when visiting a Site?
Any thing wrong your are able to identify on the following pictures?
Let’s see…
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Do you think that HSE is only for HSE professionals?
Comments?
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Comments?
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Comments?
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Comments?
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Comments?
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Comments?
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Site visits?
You, me …
We can all do our bit to point out UNSAFE situations
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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality
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Training Objectives • To give a detailed knowledge of what engineering of oil and gas facilities consist of •To describe the activities and show a sample deliverable in the various disciplines •To explain the challenges
Scope
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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality
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Design
Procurement
Manufacturing
Installation
Construction & erection
Inspection & tests
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Shipping
Hand-over
HERVE BARON Home office (Paris) •Project management •Detail Engineering (part) •Procurement
Engineering SubContractor (Delhi) Detail Engineering (part)
Shipyard (Korea) Hull Engineering & Fabrication
Satellite office (Pau) •Detail Engineering (part)
Fabrication yard (Nigeria): Fabrication (part)
Offshore (Nigeria): Installation, commissioning, start-up
Shipyards (Singapore & Malaysia) Topsides Fabrication & Integration
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Project
Engineering
Procurement
Construction
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Project
Instrumentation & Control
Layout & Piping
Process
Engineering
Procurement
Construction
Electrical
Equipment
Civil
Safety
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Engineering document register
Document revision
Discipline code A
Instrumentation & Control
C
Civil engineering
E
Electrical
G
Project general documents
J
Mechanical
K
Safety
M
Piping & Layout
P
Processes
S
Steel Structures
V
Vessels – Heat exchangers
W
Materials – Welding
Document number
Document title
A
1
48104
Service building instrument. rooms cables routing
B
A
2
48102
Trouble shooting diagrams
D
A
3
48134
F&G system architecture drawing
E
A
4
50100
Instrument index
B
A
7
50003
Spec for instrument installation works and service
C
A
8
50960
Instrument Data sheets for temperature switches
B
A
9
50110
Requisition for pressure relief valves
B
M
1
62059
General plot plan
B
M
2
62020
Piping details standard
C
1
Installation drawings
M
2
62070
Piping general arrangement Area 1
D
2
Detail drawings
M
4
60100
Special items list
D
3
Diagrams
M
5
62250
Piping isometrics booklet
C
4
Lists – Bill of Quantities
M
6
60000
Pipes and fittings thickness calculation
A
5
Isometrics
M
6
62351
Calculation note CN1 - piping stress analysis
A
6
Calculation notes
M
7
60001
General piping specification
C
7
Specifications
M
8
60103
Data sheets for station piping material
B
8
Data sheets
M
9
60200
Requisition for pipes
F
9
Requisitions
Document code
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Diagram
Key plan
Drawing
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Drawings common sizes & scales
A0 = 840x1188
A1 = 594x840 A2 = 420x594 A4 = 210x 297
A3 = 297x 420
Scale
1m =
1/1000
1 mm
1/500
2 mm
1/250
4 mm
1/100
1 cm
1/50
2 cm
1/33
3 cm
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Engineering schedule
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Engineering resources
Commissioning 9%
Electrical 9%
Mechanical Equipment 6%
Instrumentation /ICSS/Telecom 10%
Naval 4% Process 2%
Others 6%
Structural 23%
~1,000,000 man-hours Piping 31%
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Client Documents submitted to client
Approval/ Comments
Design basis:
Documents for Construction:
- Functional requirements
Construction drawings & specifications
Engineering
- Client specifications
Documents for Purchase:
bill of quantity & specification
- Design codes Documents submission
Comments
Vendors
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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality
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Design Basis
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Infrastructure:
Process facilities:
Feedstock and products flow Feedstock composition Battery limit conditions Equipment Spare
r a e r u s s e r
50
Administrative and technical buildings
45 40
Control room
35
Access road
30
Site fencing, gates, check point
25 20
Performance:
15
Products specifications
10
Energy efficiency, emissions
Design criteria:
% of over design
5 0 -85
Utilities:
Electric power supply Other utilities
-80
-75
-70
-65
-60
-55
Environment data:
Min/max temperature Rain/snow fall Wind Geological conditions
Systems:
Process control Fire/gas alarm Public address, LAN, PABX
Applicable codes and standards:
International standards Local rules
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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality
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Engineering disciplines Process Equipment HSE Civil Layout Piping Instrumentation Electrical
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Functional requirements – example of a gas compression station Gas composition
Performance
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TEG
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HP Compression & TEG Gas Injection
1200 psig 3000 psig
500 psig
200 psig
IP Compression From Wells 165 - 205 F
HP Separator 500 psig
5500 psig
50 psig
LP Compression
5 psig
Cooler
Emul. Treater 50 psig 150 F
Process Scheme Optimization
Degasser 5 psig
Oil Production
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Process simulations
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Process Flow Diagram (PFD)
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Equipment list
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Thermodynamic calculations
Heat & Material balance
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Equipment sizing
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Process data sheet
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Fluid list
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Piping & Instrumentation Diagram (P&ID)
Line List
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Piping & Instrumentation Diagram (P&ID)
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P&IDs legend & symbols
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Line sizing
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Process automations: Cause & effect chart
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Process control
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Process safety
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ESD logic diagram
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ESD simplified diagram
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Flare Report
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Operating manual
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Quiz: Is this a P&ID? a PFD?
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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical
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Process design
PFDs H&M balance
Process data sheet
Equipment specification
Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.
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Equipment list
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Rotating machinery
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Pressure vessels
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Heat exchangers
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Packages
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Process data sheet Mechanical data sheet
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Vessel guide drawing
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Material Requisition
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Bid technical evaluation
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Vendor design
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Equipment summary
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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical
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HAZOP Review RISK LEVEL RISK MATRIX
FREQENCY
SEVERITY
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HAZOP Action sheet
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Fire Fighting
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Fire Water demand calculation note
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Fire Water P&IDs
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Deluge system arrangement drawings
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Fire fighting equipment location drawing
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Passive fire protection drawing
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Passive fire protection
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Fire & Gas detection layout
Hazardous area HERVE BARON classification drawing
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Quantitative Risk Analysis (QRA)
Case stuy: Gas leak from random piping component rupture Cause: installation error, corrosion, material defect… Possible consequence: Dispersion without ignition / jet fire / flash fire / explosion Section considered: Compressor building
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Quantitative Risk Analysis (QRA)
Step 1: Identification and characterisation of initiating events
risk components *failure rate (from statistics) Σ
Gas leak inside compressor buidling due to component rupture
Frequency (event/year) Outflow rate (kg/s)
Hole size (% of component section)
5%
20%
Full
1,11E-01
5,06E-04
6,83E-05
5,7
90,8
2270,0
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Quantitative Risk Analysis (QRA)
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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
0,070
Delayed Ignition
Explosion/ Flash-fire
Consequence Event
Frequency (ev/y)
Gas detectors are provided inside the building, that 0,998 activate isolation and depressurization. Jet fire ESD & It FFis 7,779E-03 assumed that they operate 95% of the time. 0,002
Jet fire no ESD & FF
1,520E-05
Probability of explosion vs flash fire 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
Frequency (event/year) Jet fire ESD & FF 7,779E-03 Jet fire no ESD & FF 1,520E-05 Explosion 1,774E-05 1,301E-04 Flash Fire Dispersion 1,034E-01
No B04a/b/c/d
5%
Probability of delayed ignition takes into account equipment explosion protection (Ex)
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Quantitative Risk Analysis (QRA)
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Step 3: Consequence evalutation
Overpresssure (bar)
0.2
0.1
0.01
Distance (m)
96
167
1270
CONSEQUENCE CLASS
QUANTITATIVE CRITERIA
EFFECTS
MINOR
≤0.1
bar locally (within 10m)
No effect, no damage
SIGNIFICANT
≤0.1
bar locally (within 50m)
Limited damage to plant and operators
SEVERE
> 0.1 bar within plant
Damage to plant and operators
MAJOR
> 0.1 bar on populated areas
Damage to plant, operators & public
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Quantitative Risk Analysis (QRA)
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Unacceptable risk area– Design change necessary
Final step: classification of risk
Release Frequency
Immediate ESD & Fire ignition Fighting
Delayed Ignition
Explosion/ Flash-fire
Consequence Event
As Low As Reasonably Practicable – Plant Management measures Acceptable risk area
Frequency (ev/y)
0,998
Jet fire ESD & FF
7,779E-03
0,002
Jet fire no ESD & FF
1,520E-05
0,949
Dispersion
9,827E-02
0,120
Explosion
1,774E-05
0,880
Flash fire
1,301E-04
Dispersion
5,133E-03
0,070
1.0E-02
1,11E-01 Release/yr 0,930 0,028 0,051 0,972 Yes
Frequency (event/year) Jet fire ESD & FF 7,779E-03 Jet fire no ESD & FF 1,520E-05 Explosion 1,774E-05 Flash Fire 1,301E-04 Dispersion 1,034E-01
No B04a/b/c/d
5%
1.0E-03
1.0E-04
Unlikely 1.0E-05
Rare 1.0E-06
Minor
Significant
CONSEQUENCE CLASS
QUANTITATIVE CRITERIA
EFFECTS
MINOR
≤0.1
bar locally (within 10m)
No effect, no damage
SIGNIFICANT
≤0.1
bar locally (within 50m)
Limited damage to plant and operators
SEVERE
> 0.1 bar within plant
Damage to plant and operators
MAJOR
> 0.1 bar on populated areas
Damage to plant, operators & public
Severe
Major
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Environmental Impact Assessment (Air quality dispersion analysis)
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Noise Map
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dB(A)
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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical
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Process design
PFDs
P&IDs
H&M balance
Piping Instrumentation
Process data sheet
Equipment specification
Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.
Vendor drawings
Layout Civil Electrical
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Grading plan
Required finish level
Native soil elevation
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Vendor information
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Foundation Calculation
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Foundation drawing/ re-inforcement
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Foundation drawing/ Formwork
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Civil works specification
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Loading data
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Structural design
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Calculation note
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Structural drawings
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Architectural drawings
Equipment layout drawing
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Heating, Ventilation &Air Conditioning (HVAC)
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Civil Works Installation Drawings
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Standard drawings
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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical
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Process design
PFDs
P&IDs
H&M balance
Piping Instrumentation
Process data sheet
Equipment specification
Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.
Vendor drawings
Layout Civil Electrical
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Layout/ principles
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Layout/vendor drawings
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Layout/consideration for all networks
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General Plot Plan
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Unit Plot Plan
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3D modelling
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3D model clash check
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3D model review
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Equipment handling
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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical
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Process design
PFDs
P&IDs
H&M balance
Piping Instrumentation
Process data sheet
Equipment specification
Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.
Vendor drawings
Layout Civil Electrical
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Line Diagram
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Piping Layout drawing
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Isometric drawing
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Piping Pre-fabrication
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Post Weld Heat Treatment
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Piping Inspection and testing
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Piping General Arrangement drawing
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Calculations
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Standard Pipe Support drawings
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Plot Plan
Piping line diagram
Piping installation work process
Piping studies & layout
Piping 3D modelling
Piping stress analysis
Piping isometric drawing
Stress OK?
Process OK?
Piping isometric drawing IFC
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Material Selection
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Material Selection Diagram
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Process Fluids list
Piping material classes
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Piping material classes
Piping material class specification
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Piping material classes specification
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Piping material classes specification
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Piping material classes specification
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Σ
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Piping material requisition
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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical
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Piping & Instrumentation Diagram (P&ID)
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Instrument list
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Level sketch
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Instrument data sheet
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Process Control System
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System Architecture drawing
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Control narrative
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Mechanical Equipment Control
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Emergency shutdown
The instrument hardware
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Instrument room Marshalling
Controller
cabinet
cabinet
Control room
VDU
PT
JB
Process line
CPU
LAN Secondary cable
Multi cable
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Junction Box drawing
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Instrument location drawing
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Building detail drawing/ Telecom and PAGA layout
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Instrument standard installation drawings
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Junction box wiring
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Cable routing drawings
Cable list
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Instrument bulk Material Take-Off
ITEM
QUANTITY
DESIGNATION
1
195
Gauge adapter – ½” x ½”
2
37
Block manifold 2 valves (Gas) – ½”
3
23
Block manifold 5 valves (Gas) –½”
4
0
Ball valve ½” – 12mm
5
300m
6
200
Reducer – 12mm x ¼”
7
50
Union tee – 12 x 12 x 12mm
8
50
Female connector – 12mm x ½”
9
350
Male connector – 12mm x ½”
10
9
Plug – ½” NPTF
11
8
Plug – ½” NPTM
Tubing – 12mm OD x 1mm
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Cable routing inside technical room
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Instrumentation & control rooms layout
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Screen displays
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Instrument loop diagram
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Engineering Process Equipment HSE Civil Layout Piping Instrumentation Electrical
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Electrical consumer list
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Electrical Load Summary
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General One Line Diagram
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Generators
Switchgear
Transformer
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Equipment data sheet
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Switchboard Single Line Diagram
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Switchgear Typical Diagram
VOLTAGE OF MS-001 (STUDY1)
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) s t l o V ( e g a t l o V s u B
BARON 9900 9800 9700 9600 9500 9400 9300 9200 9100 9000 8900 8800 0.0
2.5
5.0
7.5
10.0 12.5 Time (Seconds)
15.0
17.5
20.0
FREQUENCY OF MS-001 (STUDY1) 50.0
) z H49.5 ( y c n 49.0 e u q e r 48.5 F s u B48.0
Calculations
47.5
47.0 0.0
2.5
5.0
7.5
10.0 Time (Seconds)
12.5
15.0
17.5
20.0
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Cable routing drawing
Cable schedule
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Typical installation drawings
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Block Diagram
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Trouble shooting diagrams
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Lighting layout
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Lighting illumination level
Iso lux curves
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Electrical equipment layout
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Electrical Control System
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Electrical Control System
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From main power generators
From emergency (diesel) generators
Electrical load shedding
To normal consummers e.g. pumps in process and utility units
To essential consummers e.g. fire water pump
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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality
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Field Engineering
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Site Query
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Site MASTER set of documents
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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality
HERVE BARON MONTH 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 PROJECT SCHEDULE 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)
5
4
1
1
2
3
5
3
4 2
5
Process BARON simulations HERVE
Process data sheet Equipment selection & purchase Vendor data
Foundation drawings
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Engineering schedule
Safety valves duty & data sheet (Process)
Size & weight estimates
Estimates must be done Safety valves inquiry and purchase (procurement)
Safety valves location & piping routing (piping/layout)
to meet the schedule
Piping calcs & supports (piping/stress) Steel structure design and drawings (civil)
Supports & loads estimates Purchase steel (manufacturer)
Safety valves sizing & drawings (vendor)
Fabrication (manufacturer) Shipping
Structure at Site
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What the Vendor supplied
What Engineering designed
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Oil & Gas Engineering Training HSE Moment Intro, scope & objectives Project Engineering The Design Basis Discipline presentations Field engineering Schedule Quality
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Engineering Quality Assurance:
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Engineering document register
Document number
Document title
Document revision
A
1
48104
Service building instrument. rooms cables routing
B
A
2
48102
Trouble shooting diagrams
D
A
3
48134
F&G system architecture drawing
E
A
4
50100
Instrument index
B
A
7
50003
Spec for instrument installation works and service
C
A
8
50960
Instrument Data sheets for temperature switches
B
A
9
50110
Requisition for pressure relief valves
B
M
1
62059
General plot plan
B
M
2
62020
Piping details standard
C
M
2
62070
Piping general arrangement Area 1
D
M
4
60100
Special items list
D
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Engineering Quality Assurance: Document checking and distribution
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Engineering Quality Assurance: Document revision
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Engineering Integrity: Site Query from Construction
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Interface Agreement
Section/Step 1
Section/Step 2
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Interface definition
