Engineering Management Training

HERVE Engineering Management Training
BARON
Welcome to this presentation
This is a preview of my 3 day
Engineering Management training
I hope you will enjoy it and attend the next training session, which
will be held on Oct 23rd-25th in Yogyakarta, Indonesia
© 2013 – Hervé Baron

Hervé Baron
HERVE Training objectives & scope
BARON
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

HERVE Training Agenda
BARON
Day 1
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
BARON
Day 2
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

BARON
Day 3
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

BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE Basic Engineering/FEED
BARON
Client
Vendors / Sub-
Documents Approval/ Contractors
submitted to Comments
client Inquiries Quotations
Cost Estimate Department

Documents for Inquiry:
Bill of Materials / specifications
Process Design
Package (PDP) Engineering
Client
Engineering basis for EPC call for
tender
Material Requisitions for LLI

HERVE The Engineering Work process synoptic
BARON
Process design
PFDs P&IDs
H&M balance
Piping
Instrumentation
Equipment specification
Process
data sheet Vendor
Rotating drawings Layout
Pressure vessels
Fired equipment Civil

Heat exchangers
Electrical
Packages etc.
BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE List of common Engineering Deliverables
BARON

HERVE Specifications
BARON
What difference can you see between the 2 sets of specifications?

Design criteria for civil, structural and building Technical specification – structural steel materials and
engineering 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
Technical specification for wheeled fire extinguishers
Design philosophy for cathodic protection
Technical specification for isolating joint
Specification for pipe supports design
Technical specification for cathodic protection materials

Job specification for supply for piping sliding plates
Technical specification for centrifugal pumps

Technical specification for tail gas incinerator
HERVE The (Basic) Engineering Design Data
BARON
Draw the
Table of
Contents

BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE Engineering disciplines: activities and deliverables
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

HERVE Process design criteria
BARON
• Design margins
• Design Pressure and Temperature criteria
• Equipment sizing criteria
• Line sizing criteria
• Control valve sizing criteria

HERVE Engineering disciplines: activities and deliverables
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

HERVE Process simulations
BARON
Simulator settings
Output
Input
- Flow scheme
- Stream flows and
- Feed composition and - Thermodynamic model
composition
conditions - Equipment performance
- Equipment duty

HERVE Block Flow Diagrams & Process Flow Diagrams
BARON

HERVE The Process Flow Diagram (PFD)
BARON
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

HERVE Process eqiupment sizing
BARON
Case study: Production separator
Sets the gas

cross section
Vessel size
Sets the liquid volume

HERVE Process Data Sheet
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)
HERVE Piping & Instrumentation Diagram (P&ID)
BARON
What purpose does a

P&ID serve?
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
During operation:
• Reference drawing for operator, work permit, plant modifications etc.
HERVE Piping & Instrumentation Diagrams (P&IDs)
BARON
Important features (1/3)

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 Piping & Instrumentation Diagrams (P&IDs)
BARON
Various types of P&IDs

P&ID
• Legend and Symbols representation
• Identification & Numbering
• Details and Typicals
• Process or Utility P&ID
• Distribution P&ID
• Interconnection P&ID
• Pumps auxiliary P&ID Details
• Package P&ID

HERVE P&ID work sequence
BARON
P&ID
HAZOP
Review
IFR IFD IFC

Piping MTO

& PO
HERVE Quiz
BARON
Which revision of P&IDs has the following purpose/contents?
Purpose IFR IFD IFC
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 IFR IFD IFC
Comments from all disciplines
Comments from Piping, I&C disciplines
Finalized interfaces with eqt/package
Exercised Contract Option(s)
Size, number of PSVs and CVs

Diameter of process lines
Diameter of utility lines
HAZOP comments incorporated
Client comments incorporated
HERVE Process Engineering / schedule
BARON
Hands-on exercise

HERVE Typical PROCESS Licensor / Engineering split
BARON
Item Process Licensor Engineer

PFD, H&MB X
Equipment data sheet Equipment process data sheet: Equipment Mechanical data sheet
- Operating conditions,
- Duty
- Diameters of vessels
- Size of Nozzles
- Pump head
+ specific info for internals etc.
P&IDs Generic customized (piping class, line and
valves size, HAZOP comments,
vendor info)

Line sizing Line sizing criteria Sizing (takes into account eqt loc,
elevation etc.)
Plot Plan recommendations X
Material selection Basic requirement MSD
BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE From Process to Mechanical
BARON
Process design
PFDs
H&M balance
Equipment specification
Process
data sheet
Rotating
Pressure vessels
Fired equipment

Heat exchangers
Packages etc.
HERVE Process Data Sheet vs Mechanical Data Sheet
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 Process Data Sheet vs Mechanical Data Sheet
BARON
Process Data Sheet: Mechanical Data Sheet:

• design conditions • design conditions & code
• skeleton drawings • scaled drawing
• material (generic type) and • material grades and thickness of
corrosion allowance all parts
• equipment dimensions • all dimensions
• definition of type of internals • drawings of internals
• nozzles list • nozzzles position and elevation
• height from ground • designed support
• weight
• loads on foundation

• limits of supply
HERVE Mechanical Design
BARON
The vessel wall thickness is calculated so that with all

loadings, i.e.,
• Internal pressure
• External pressure
• Weight
• Seismic
• Wind
• Other external loads

HERVE Equipment / Mechanical
BARON
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 ?
What are the key things to consider

when specifying a package?

HERVE Instrumentation Specification for packaged units
BARON
Local control Centralized control

HERVE Test
BARON
Identify the documents issued by Engineering to order each type of

equipment…
Equipment Process discipline Equipment/Mechanical discipline

PDS Duty MDS Particular General MR
spec Specification Specification
Pressure Vessel
Rotating equipment
Reactor
Heat Exchanger – Shell &
Tube
Heat Exchanger – Other type
Fired heater

Package
BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE HAZOP
BARON
hands-on exercise
Fill the table

HERVE Quantitative Risk Analysis (QRA)
BARON
case study: gas leak in Turbo-compressor building
Step 2: Event tree analysis

Release Frequency Immediate ESD & Fire Delayed Explosion/ Consequence Event Frequency (ev/y)
ignition Fighting Ignition Flash-fire
Probability of immediate ignition Gas detectors are provided inside the building, that
for 1-50 kg/s release rate is 7% 0,998 activate isolation and depressurization.
Jet fire ESD It& is
FFassumed 7,779E-03
(from statistical data) 0,070 that they operate 95% of the time.
0,002 Jet fire no ESD & FF 1,520E-05
Probability of explosion vs flash fire (12%) depends
1,11E-01
Release/yr
on mass of gas and degree of confinement
0,949 Dispersion 9,827E-02
0,930
0,051
0,028
0,120
0,880
Explosion
Flash fire
?
1,774E-05
1,301E-04
0,972 Dispersion 5,133E-03
Yes 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

No Flash Fire 1,301E-04
Dispersion 1,034E-01
B04a/b/c/d 5%
What is the frequency of an explosion?

BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE Foundation guide drawing
BARON

HERVE Pipe-rack design
BARON
What is usually the governing load?

What is the governing design criteria?

BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE Layout/principles
BARON
Define the respective position of the 6
items as per good plant layout practice
PREVAILING WIND
…
… … … … …
3 6
1

2
5
HERVE On-shore plant: Equipment spacing recommendations
BARON
as per GE GAP Guidelines 2.5.2

HERVE Layout principles: typical Unit Layout
BARON

HERVE Piping installation
BARON

Unit Plot Plan Line diagram
HERVE Piping routing
BARON

HERVE Piping design iso vs Shop iso
BARON

HERVE Piping Installation work process
BARON
PFD
Piping Piping Piping Stress

Plot Piping 3D
line studies & isometric OK?
Plan modelling
diagram layout drawing
Process
eqt list
Piping
1st Piping MTO: 2nd Piping MTO, isometric
for Inquiry for Order drawing
IFC
IFC
IFR IFD Final Piping
P&IDs
P&IDs P&IDs MTO

HERVE Quiz
BARON
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

BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE Process Control System
BARON
Case of Package
controlled by Central
Process Control
System
What documents from

the package Vendor are

needed by the DCS
Vendor in this case?
BARON
Day 1

Generalities

• PROCESS
• MECHANICAL
• CIVIL
• INSTRUMENTATION

• ELECTRICAL
HERVE Electrical consumer list
BARON

BARON
HERVE
BARON
HERVE
HERVE Quiz: Electrical Engineering input data
BARON
Guess the title of the documents
Process Piping &

Layout
Document?
Document?
Electrical Electrical
Vendor Document? Equipment

Electrical specs
Document?
Document?

BARON
Day 2

• IT

HERVE Define the Engineering schedule
BARON

BARON
Day 2

• IT

HERVE ENDORSEMENT: case study
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.
2. 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?
62
BARON
Day 2

• IT

HERVE Engineering Split of work
BARON
What is the typical

share of manhours
done in home office
versus low cost
center?
Discipline Paris (%) India (%)

Process/HSE Design
Equipment
Electrical
Instrumentation

Civil
Piping
HERVE Engineering Split of work/Piping
BARON
Horizontal split

HERVE Engineering resources
BARON
Civil Designer
Job scope & purpose Preparation of design deliverables based on
Engineer’s plans
Key responsibilities • Organization and co-ordination of design
and drafting studies resulting in the
production of
• Detailed drawings
• Bill of quantities
• Etc.
• Development of drawings, models using
CAD systems
Education Diploma in Civil Engineering / Drafting
Work experience 5 years of related worked experience
Management responsibilities Organizes the work of draftsmen

Computer skills Drafting (CAD) softwares
BARON
Day 2

• IT

HERVE The Engineering work sequence
BARON
Fill the missing captions

HERVE Piping & Instrumentation Diagram (P&ID)
BARON
Which disciplines provide input to P&IDs?

BARON
Day 2

• IT

HERVE BASIC vs DETAIL design
BARON

HERVE Conventional scheme vs CCFT scheme
BARON
FEED CFT PROPOSAL BID APPRAISAL FID EPC
CTR commitment on LS Equipment Requisition IFP
CCFT
CCFT SELECTION OF ENGINEERING

FID EPC
CONTRACTOR CONTRACT
CCFT
Equipment Requisition IFP

In your opinion, what are the advantages of the CCFT
scheme
CTR commitment on LS
• For the contractor
• For the Company
BARON
Day 2

• IT

HERVE Origin of changes
BARON
Identify the likely impact of the Engineering reviews on the design
Plot P&IDs Design Blast ESD New New New

Plan criteria resistance logic valves instruments accesses
HAZID
HAZOP
QRA
P&ID
review
3D
model
review

SIL
review
BARON
Day 3

• FEED
• EPC

• The plan

HERVE Critical path of an Oil & Gas Project
BARON

HERVE Key Engineering Milestones for an EPC
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

HERVE Vendor drawings necessary for design development
BARON

HERVE Typical level 1 EPC Project Engineering schedule
BARON

BARON
Day 3

• FEED
• EPC

• The plan

HERVE Safety Engineering
BARON

In your opinion, how is Safety performing?
HERVE Engineering progress KPIs
BARON

BARON
Day 3

• FEED
• EPC

• The plan

HERVE EPC Key Engineering Milestones and benchmarks
BARON
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 Additional Milestones for Off-Shore jobs
• Primary steel drawings IFC

Please assign to each Milestone a schedule benchmark:
Project start + X month, for a typical 36 months Project
HERVE Engineering Manhours benchmarks
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?
• ???? manhours

Please guess…
HERVE Engineering Management Training
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
Training experience Professional experience/Companies worked with

Developer and instructor of IFP Training’s • TOTAL, for 4 years
• Engineering Management Training (8 sessions held), • SAIPEM, for 8 years
• Project control training (6 sessions held), • TECHNIP, for 6 years
HERVE You are Welcome!
BARON
The next session of the Engineering Management Training will be held:
Oct 23rd – 25th, 2013
Yogyakarta, Indonesia
To enroll, please contact Rhenindo:

www.rhenindo.com
Farida Andriyani, farida@rhenindo.com

Tel: +62 21 8493 5274 / Mob: + 62 818 737 800
See you a the training!

Engineering Management Training - Herve Baron

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HERVE Engineering Management Training

Welcome to this presentation

This is a preview of my 3 day

© 2013 – Hervé Baron

To get familiar with both BASIC and DETAILED Engineering

To know the work of the various Engineering disciplines and get

To understand the challenges faced by Engineering

To provide you with practical tips on how to control engineering

© 2013 – Hervé Baron

Engineering in the Project: Role, Organization, Documents,

General documents, Design basis and design criteria

The engineering disciplines

© 2013 – Hervé Baron

Hands-on – mini EPC Project

Key aspects of Engineering

© 2013 – Hervé Baron

The main challenge: meeting the Project schedule

How to control a Contractor

© 2013 – Hervé Baron

Engineering in the Project: Role, Organization, Documents,

General documents, Design basis and design criteria

The engineering disciplines

© 2013 – Hervé Baron

Cost Estimate Department

© 2013 – Hervé Baron

© 2013 – Hervé Baron

Engineering in the Project: Role, Organization, Documents,

General documents, Design basis and design criteria

The engineering disciplines

© 2013 – Hervé Baron

© 2013 – Hervé Baron

What difference can you see between the 2 sets of specifications?

Fire Protection Design Technical specification for fire detection devices in

© 2013 – Hervé Baron

Technical specification for centrifugal pumps

© 2013 – Hervé Baron

Engineering in the Project: Role, Organization, Documents,

General documents, Design basis and design criteria

The engineering disciplines

© 2013 – Hervé Baron

© 2013 – Hervé Baron

© 2013 – Hervé Baron

© 2013 – Hervé Baron

© 2013 – Hervé Baron

© 2013 – Hervé Baron

Results from process simulations

© 2013 – Hervé Baron

The individual drawing item of the PFD is the Equipment Item

Sets the gas

Sets the liquid volume

© 2013 – Hervé Baron

© 2013 – Hervé Baron

What purpose does a

© 2013 – Hervé Baron

Important features (1/3)

© 2013 – Hervé Baron

Various types of P&IDs

© 2013 – Hervé Baron

IFR IFD IFC

© 2013 – Hervé Baron

© 2013 – Hervé Baron

© 2013 – Hervé Baron

Item Process Licensor Engineer