DESIGN & ENGINEERING

OF EPC PROJECTS

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2
Agenda

INTRODUCTION TO EPC PROJECT MANAGEMENT

EPC PROJECT MANAGEMENT WORK FLOW
ENGINEERING DOCUMENT ISSUANCE PURPOSE
ENGINEERING WORK FLOW
PROCUREMENT WORK FLOW
ON SHORE PROJECT SCHEDULE AND SCHEDULE DEPANDANCY
WORK FRONT CONCEPT

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Introduction

❑ This presentation describes Engineering Procurement &

Construction (EPC) projects, which use Engineering
Procurement & Construction contracts.

❑ If a company is a contractor for EPC projects, they

perform the activities of design, procurement and
construction.

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EPC Project Management
- Introduction

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EPC Project Management

EPC stands for Engineering, Procurement, Construction and is a prominent form of contracting
agreement in the construction industry.

The engineering and construction contractor will carry out the detailed engineering design of the project,
procure all the equipment and materials necessary, and then construct to deliver a functioning facility or
asset to their clients. Companies that deliver EPC Projects are commonly referred to as EPC
Contractors.

The EPC phase of the project is also known as the Execution phase which normally follows what is
know as a FEED or Front End Engineering Design phase. The FEED is a basic engineering design used
as the basis for the EPC phase.

The FEED can be divided into separate packages covering different portions of the project. The FEED
packages are used as the basis for bidding on when the client offers the EPC work to the market.

Under an EPC contract, the contractor designs the installation, procures the necessary materials and
builds the project, either directly or by of the work.

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EPC Project Management

In some cases, the contractor carries the project risk for schedule as well as budget in return for a fixed
price, called lump sum LSTK depending on the agreed scope of work.

◼ EPCM stands for Engineering, Procurement, Construction Management. This type of contract is
different to an EPC Contract in that the Contractor is not directly involved in the construction but is
responsible for administering the Construction Contracts.

◼ EPCI stands for Engineering Procurement Construction and Installation which is a common form of
contracting arrangement in the Offshore Construction Industry. As opposed to an EPC contract, the
offshore facility or vessel that is constructed has to be transported and installed at the project
location.

◼ EPIC stands for Engineering Procurement Installation Commissioning is typically a Lump Sum Turn
Key (LSTK) type Contract integrating the responsibility going from the conception to the final
acceptance of one or more elements of a production system. It can be awarded for all, or part, of a
field development.

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EPC Project Lifecycle

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EPC Project Organization

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EPC Project Organization

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Engineering Discipline

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EPC Project Management
- Work Flow

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Engineering Work Flow
Engineering work flow concept is required to be fully understand for someone who involved in the EPC
Planning and Activity Sequencing.

This concept is applied when the EPC level 4 schedule is developed.

The process of engineering work to produce the required deliverables depends on not only within the
functional discipline itself but also among the process, mechanical and piping engineering functions.

Engineering in EPC project is the task of translating a set of functional requirement into a full set of
drawings and specifications depicting every detail of a facility,

Engineering involves varieties of specialties, which include :

◼ Process
◼ Civil and Structure
◼ Mechanical
◼ Piping
◼ Electrical
◼ Instrumentation
◼ General Engineering
◼ Safety

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Engineering Work Flow
There are many interdependencies between engineering documents.

For instance piping routing drawings are issued after the process diagram Is defined.

Most of the documents will usually issued several times, at different stages to for review as well as to
incorporate the comments.

Typically a document is first issued for Internal Review (IFR) of the other disciplines, then to client for
comment (IFC), it will be returned to be incorporated with the client comments and issue for Approval
(IFA), then for construction (IFC) and last once everything is confirmed and will Approve for Construction
(AFC)

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Engineering Work Flow

The entire strategy is dependent on Engineering and

Procurement providing their deliverables to meet Path for
Construction.

Contractor mobilizes based on Engineering forecast of IFC

EWPs (Engineering Work Packages).

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Engineering Work Flow
Engineering phase is very much concerned with documentation.

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Engineering Work Flow
Project Execution

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Engineering Document –
Issuance Purpose

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Engineering Document – Issuance Purpose
Project Execution – Issuing Purpose

Lead Engineer
Client Approved
Submission to Client
review

Revision
New work Comments
work
allocation
allocation

Production
Input to other
disciplines

Fail
QC

Pass
Archive by
DC
Comments
IDC

Accept Reject
QA

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EPC Project Management
- Engineering Work Flow

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Engineering Work Flow
Typical Instrumentation Engineering Work Flow

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Engineering Document Review Cycle

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Engineering Work Flow – Process Design

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Piping Engineering Flow

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 3D
Modeling
(Skid
Project)

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Skid 3D Modelling – Piping GA as Example

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Engineering Work Flow
Process, Piping & Mechanical Engineering

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Engineering Work Flow
Piping and Pipe line

• Preparation of Piping Layout.

• 3D Modeling

• Design calculations

• Preparation of Technical Specifications

• Preparation of PMS/VMS

• Route Survey Layout

• Pipeline Alignment Sheets

• MR ,TBE & Vendor Follow-ups.

• Development of Detail Piping drawings including

• Isometrics, GA’s

• Bill of material/Quantity

• Stress Analysis & Reports

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Engineering Work Flow
Mechanical

• Equipment Drawings and Specifications:

• Heat transfer equipment (Heat exchangers, Fired

heaters)

• Preparation of Datasheets for Rotary Equipments

• Pressure Vessels ( Columns, Vessels &

Tanks) as per ASME sec VIII division 1 & 2,
API 650 & 620

• Fabrication Detailed Drawings, Including BOQ’s

• Mechanical Datasheets

• Preparation of MR , TBE & Vendor Follow up

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Engineering Work Flow
Civil & Structural

• Structural GA Drawings

• Civil Foundation Design

• Civil Architectural Layouts

• Blast Design of Buildings

• Structural calculations & Analysis

• Structural Steel Jackets-Mooring, Loading equipment

• Lifting Analysis and calculation

• Bill of Quantities (BOQ)

• Bar bending schedule

• Structural Detail Drawings

• Shop/Fabrication Drawings

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Engineering Work Flow
Process & HSE

• Simulation Study Report

• Hydraulic Design Calculation

• Equipment Sizing Calculations

• Development of PFD/P&ID’S

• NPSH Calculation

• Process Datasheets

• Line Sizing Calculations

• Heat Exchanger Design

• Pump Sizing & Selection

• Fire fighting systems design

• Control Valve Calculations & TCV/PCV/PSV Datasheets

• HAZOP, HAZID & SIL Study documentation & participation

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Engineering Work Flow
Electrical & Instrumentation

• Load list / Power balance

• Single Line diagrams

• Specifications & datasheets

• Cable schedules

• P&ID’s

• Instrumentation & I/O List

• Layouts & Installation details

• Hook-ups & Loops

• JB termination

• Substation & control room design

• As-Built revision Drawings in to SPEL & SPI software

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Engineering Work Flow – E&I

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Engineering Work Flow – Instrumentation

TYPICAL INSTRUMENTATION DELIVERABLES

Instrument Index
Instrument I/O List
Instrument Data sheet
Instrument Hookup Diagram
Instrument Loop Diagram
Instrument Layout Diagrams
(Control Room Layout, Inst. Location Layout, Instrument Tray Layout Diagram)
Instrument Cable Schedule, Junction Box Schedule, Inst. Air Header Schedule
Instrument Logic Diagrams (Based on Cause & Effect Diagrams)
Instrument MTO

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Engineering Work Flow – Instrumentation

I/O List contains of instrumentation which serve as an input or output of control system.

Hence the tag number that physically has a cable which connects to the control system
appears on I/O list.

Instrument index is a document containing list of instrument devices within a plant.

Instrument index shall include tag number of all physical instruments.

I/O Count will determines the required capacity of a system

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Engineering Work Flow – Instrumentation
Typical P&ID & Process Data

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Engineering Work Flow – Instrumentation
Typical Inst. Index

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Engineering Work Flow – Instrumentation
Typical I/O List

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Engineering Work Flow – Instrumentation
Typical Instrument Loop Diagrams

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Engineering Work Flow – Instrumentation
Typical Instrument Hookup Diagrams

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Engineering Work Flow – Instrumentation
Typical Instrument Layout Diagrams

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Engineering Work Flow – Instrumentation
Typical Instrument Layout Diagrams

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Engineering Work Flow – Instrumentation
Typical Instrument Layout Diagrams

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Engineering Work Flow – Instrumentation
Typical Instrument Cable Schedule, JB Schedule

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Engineering Work Flow – Instrumentation
Typical Cause & Effect Dia. & Instrument Logic Diagram

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Engineering Work Flow – Instrumentation

Instrument Data Sheet

Instrument Data Sheet is a document containing specification and information of an

instrument device.

Instrument Data Sheet specifies general information of instrument such as tag number
identification, service description, location (line number/equipment number), P&ID
number or drawing number reference, process data (if applicable), calibrated range (if
applicable), material, performance details (such as accuracy, linearity – if applicable),
hazardous certification (for electrical device), accessories required, etc. The details of
information in data sheet may differ among each types of instrument such as
transmitter, switch, gauge, control valves.

Reference document: Piping and Instrumentation Diagram (P&ID), Heat and Material
Balance (HMB), line list, instrument specification, piping specification, calculation,
vendor catalog.

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Engineering Work Flow – Instrumentation
Typical Inst. Data Sheet

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EPC Project Management
- Procurement Work Flow

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Procurement Work Flow

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Typical On-Shore Schedule
and Dependencies

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 Typical
Project
Schedule

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Work Front Concept

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Work Front

Milestones associated with Construction: These are the IFC Plot Plan, a pre-requisite to start any site work, and
the IFC P&IDs, a pre-requisite to the issue of Piping isometrics. The 5O% IFC Piping isometric milestone comes
next, which typically falls half way through the Project, as ensuing works, such as pre-fab and erection have a rather
incompressible duration, due to site constraints (capacity of pre-fab shop, space constraints for erection limiting the
progress).

Even if engineering deliveries are in sequence, the above engineering progress measure might still be deceiving, as
it will only reflect the amount of engineering work completed and not the Workfront made available to construction.

let's consider for instance that two foundations are to be cast. The first one is a very large foundation and the second
one a small one. Issuing the drawing of either the large or small foundation will earn engineering the same progress,
although it will open quite a different Workfront to Construction.

One sees the necessity to measure the issued Workfront.

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Work Front

In the case of foundations, for instance, this will be done by monitoring the cumulative quantity of concrete (m3) of all
issued IFC foundation drawings.

Producing an S curve, such as the one shown in next slide, showing both planned and actually issued quantities will
give a true picture of how well engineering is supporting civil works.

One will similarly monitor, for an On-Shore project, the cumulative quantity of steel (tons) of issued IFC Structural
drawings.

The cumulative tons (or dia inch) of IFC issued Piping isometrics will show the available piping Workfront.

Such progress curves, showing the actual versus planned available work fronts are instrumental to monitor
engineering progress, identify shortage and take corrective actions (increase mobilisation).

It is not perfect however and can still be deceiving, in case of out-of-sequence issues: engineering may have issued
drawings representing significant quantities, but that does not generate construction workfront as such works can not
be performed at this time (due to lack of access or pre-requisite for another work to be completed before, for
instance).

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Work Face Planning

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 HARD
DRIVE
WORKCONTROL
BUT……

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