Universitas Riau Kepulauan 23 Juni 2014 Introduction to Oil and Gas Facilities Engineering Project; Steps of Project Engineering: Engineering Management : Reasons to be an Engineer in Oil & Gas Industry Q & A
Content 3 Oil & Gas Process Chain Upsream Oil & Gas Life Cycle PRODUCTION START-UP DISCOVERY WELL NEW EXPL . INITIATIVE PRODUCTION DEVELOPMENT EXPLORATION & APPRAISAL PROJECT DEVELOPMENT LIFE CYCLE Project Development Life Cycle 5 Assess the value of the opportunity and the alignment with business strategy based on preliminary reservoir scenarios and development concepts Refine selected concept, complete tendering and produce a Project Execution Plan which allows project sanction Generate concept alternatives, select and optimise the preferred concept based on technical, economics and risks evaluation Execute the project to achieve a fully operating system meeting cost, time and quality targets Start up, operate and evaluate the asset to maintain performance & maximum return to shareholders. O b j e c t i v e
Does the opportunity support an economic development? M a i n
Q u e s t i o n
Is the asset ready for production ? What lessons learnt can be shared with other projects ?
Commissioni ng, Start-Up and Perf. Test Gt1 Gt2 Gt3 Hand over Can the planned project be successfully executed and create value? Is the selected concept the optimal development alternative? Value Realization Value Identification Do the Project Right Choose the Right Project Discovery Evaluation Screening Basic Design, Tender, FEED Selection of the Preferred Option (s) of the Development EPCI Well Operation Pre-Commissioning Commissioning Production Start-Up Project Evaluation Close Out . A c t i v i t i e s
Commissioni ng, Start-Up and Perf. Test Gt1 Gt2 Gt3 Hand over . Engineering Workflow Study Preparation Basic Design FEED Detail Engineering Construction, Installation & Pre- Comm Commissioning & Production Startup Study Preparation Objective To define preliminary facilities layout and treatment plant options on the basis of the existing production parameters evaluation, drilling development options and other constraints To estimate expenditure with the degree of uncertainty expected in the different exploration and development project phases To estimate the technical and economical feasibility of the different facilities concept alternatives. Deliverables
Pre-feasibility study (evaluation phase) Feasibility study (concept selection phase) oBlock diagrams oProcess schemes oGeneral layout oConstruction and installation
oBlock diagrams oFacilities schemes oGeneral layout oMain equipment general arrangement oSite technical requirements oConstruction and installation criteria o Cost/Schedules estimates Basic Design Objective To specify the content of the work carried out during the Detail Engineering phase and point out critical design aspects. To define the project specifications and tender documents for the Detail Engineering and Construction phase and for the acquisition of critical items. To define and identify the project elements to a level of technical completeness sufficient to evaluate their initial and operating costs with a target accuracy of 20% for plants and equipment and of 10 % for structural items. Deliverables
Basic Design Book. oFacilities Technical documents (schemes, layout etc.) oTechnical Specifications for long lead items oEquipment lists Decommissioning Study Risk Management Plan (Update) Maintainability / Operability Philosophy. Constructability and installability analysis. First version of Project Development Plan (PDP). oProject Scope for Joint Ventures and Authority approval oDescription of selected concept oCreation/alignment with Business Plan oDevelopment Schedule Cost Estimates. Information Communication Technology Strategy and implementation plan. Logistics Plan FEED Objective To update and complete the Basic Design results. To define the project specifications and tender documents for the Detail Engineering and Construction phase and for the procurement of critical and Long Lead Items. To define and identify the project elements to a level of technical completeness sufficient to evaluate their initial and operating costs with a target accuracy of +/-15% based on documented cost definition of main and secondary items and systems from Vendors and market analysis. To prepare more accurate time schedule . Deliverables
FEED Design book. oFacilities Technical documents (schemes, layout etc.) oTechnical Specifications for long lead ad main items oUpdated Equipment lists oDevelopment Schedule Decommissioning Study Logistics study and functional specifications Constructability and installability analysis. Revised documented Cost Estimates. Detail Engineering (1/2) Objective Design all plant systems, structures, items and bulk materials with the detailed information needed for their procurement, construction, transportation and installation. Prepare the necessary documentation Approved for Construction, including specifications for materials to be acquired and adequate procedures to support the planned operations. Support the engineering activities related to material procurement, construction, transportation, installation and pre-commissioning. Manage the activities deriving from changes and integrations arisen during all the above said activities up to the Handover. Deliverables
Detail Engineering book including: o Final Technical Specifications o As built General plant layout and arrangement drawings o As built PFD and P&ID o Final Equipment and Instrument Data sheets o Final as built drawings o Final structural reports and drawings o As-built 3D model o Final material list o Final Architectural design studies and drawings o Final weight control report oRoutes plan and profiles Detail Engineering (2/2) Deliverables
Final ESD study Final Hazard reports Environmental compliance reports Waste management report SCADA reports Final project IT Plan Final document list Transportation Plan Test run specifications
Reference Cost database Engineering CAPEX Engineered Equipment CAPEX Bulk material CAPEX Construction CAPEX Operating plan and procedures (Data- books and Operating Manuals) Construction, installation, hook up plan Logistics plan Operating directions (Precommissioning, Commissioning, Start-up, Normal Operations, Emergency Operations, Stop) Specifications related to test run Commissioning Plan
Estimated operation and maintenance Opex DECAB Estimate CAPEX/OPEX & DECAB ESTIMATE at the Execution level
Construction, Installation & Pre-Commissioning Objective Organize construction, installation, hook-up activities and pre-commissioning at site according to the following: Onshore/Offshore Constructions at Contractors/Vendors sites; i.e. construction and pre-fabrication of equipment, tubing and components for treatment facilities, off-shore structures, etc. This may be carried out at a Contractor/Vendor workshop or at a work area situated (on the coast) close to the plant site. Onshore Construction on Company sites; i.e. construction of treatment plants, pipelines and components. When large spaces are available close to the construction site most of the plant may be built there. Such spaces may also be used for locating Contractors/ Vendors stores and warehouses. Offshore Constructions in Company Areas; i.e. installation of jackets, decks and flowlines and corresponding hook-up. This activity usually requires large cranes barges for pre-fabricated jackets, decks and skids installation and for following hook-up activities
Fabrication, Construction, Installation & Hook-up Material Manufacturing Plant Operations Manual o Contractors/Vendors Operating and Maintenance Manual o Data Books Pre-commissioning plan and procedures Construction Reporting Construction engineering book Operation Permit (for Precommissioning) Certification documents Test run Specifications As-built drawing and documents Non-Conformity Reports Spare parts lists and exceeding materials lists Data book o Technical Specification o Data sheets o As-built drawings o As-built 3D model
Installation, operation and maintenance manual o Test run specifications o Operating plan and procedures o Spare parts list Pre-Commissioning Test run specifications, including: o Disposal of hazardous hydrocarbons during testing o Commissioning procedures for introducing hydrocarbons Mechanical Completion Certificates, including: Testing Certificates Operation permit As-builtdrawings and documents Commissioning and Start-up Plan, including: Availability of human resources for start up Personnel Training Certificates
Construction, Installation & Pre-Commissioning Objective Commissioning: The main objective of this activity is to verify the proper running of all components of asset and to test the overall process, output, quality and performance against design specifications. Start Up: Once the Commissioning has ended with positive results the Start Up can begin, aimed at reaching the plant nominal operating conditions Performance Test: This activity, also named Test Run, is the final test operated in the plant in order to verify that the global throughput of the plant, and its related subsystems, corresponds to the contractual requirements and that it can be satisfactorily operated in any operating condition. Deliverables
Performance Test certificate Risk Assessment Report Operations Organisation Plan Start Up certificate .As-built. Documentations and Drawings Facilities acceptance report Functional and Static Reports DHVS Test Report Well Maintenance Plan Wells Final Report OJT Scheduling, Evaluation and Final Reports. Engineering Organization Chemical Engineering Process Process Safety Flow Assurance Mechanical Engineering Piping Pipeline Mechanical Civil Engineering Civil Structure Ocean/Offshore/Naval Engineering Offshore Structure Subsea Pipeline Marine/Naval Physic Engineering Instrument Subsea Control Electrical Engineering Electrical Material/Metalurgy Engineering Material Welding Coating/ Corrosion Engineering Schedule 17 Examples of communications initiated by the EPC Contractors EPC Contractors Oil Company Project Team Technical Queries (TQ) (request for clarifications related to the work package)
Deviation Requests (DR) (request to deviate from a specification)
Variation Order Proposals (VOP) Communication with EPCI Contractor 18 Examples of communication initiated by the Oil Company Project team: EPC Contractors Oil Company Project Team Non-Conformity Reports (NCR)
Company Instructions (CI) (contractual changes initiated by the Company)
Variation Orders (VO)
Interface Issues (II) (management of the interfaces across different Contractors) Communication with EPCI Contractor Life of Field Vendors & Manufacturers EPCI Companies Operator Operator: ConocoPhillips, Total, Chevron, Pertamina, Saka Energy, ENI, INPEX, Saudi Aramco, etc. EPCI Companies: SAIPEM, JGC, Tripatra, Rekayasa Industri, IKPT, Worley Person, Subsea 7, Swiber, etc. Vendors & Manufacturers: Honeywell, Swagelok, Duco, FMC Technologies, Royce Rolls, Kawasaki, One Subsea, etc. Designing a Field Development 20 Reasons to be an Engineer in Oil & Gas Industry The seven fundamental areas of competence in the engineering discipline are : materials design construction inspection testing Maintenance Operation 7 Essentials of Successful Engineering Recruitment Process/Step Process Fresh Graduate Experience Administration Screening Psikotest
Technical Test
Interview Psikologi
Group Discussion
Interview [User] Interview [Manager/BoD] Salary offering Medical Test PASS or FAIL Engineering Resume