ManagingEngineering,Procurement,Construction, andCommissioningProjects Managing Engineering, Procurement, Construction, and Commissioning Projects A Chemical Engineer’s Guide Avinashkumar V. Karre Author AllbookspublishedbyWILEY-VCHarecarefully produced.Nevertheless,authors,editors,and AvinashkumarV.Karre publisherdonotwarranttheinformation WorleyGroupInc. containedinthesebooks,includingthisbook, 4949EsssenLane tobefreeoferrors.Readersareadvisedtokeep 70809BatonRougeLA inmindthatstatements,data,illustrations, UnitedStates proceduraldetailsorotheritemsmay inadvertentlybeinaccurate. CoverImage:©nostal6ie/Shutterstock Contentsinthisbookaresolelybasedon LibraryofCongressCardNo.:appliedfor theauthor’sextensiveworkexperience andknowledge.Ifpartofthebookor BritishLibraryCataloguing-in-PublicationData somecontentsmatchwiththeexternal Acataloguerecordforthisbookisavailable source,itwouldbeconsideredmerelya fromtheBritishLibrary. coincidence. Bibliographicinformationpublishedby theDeutscheNationalbibliothek TheDeutscheNationalbibliotheklists thispublicationintheDeutsche Nationalbibliografie;detailedbibliographic dataareavailableontheInternetat <http://dnb.d-nb.de>. ©2023WILEY-VCHGmbH,Boschstr.12, 69469Weinheim,Germany Allrightsreserved(includingthoseof translationintootherlanguages).Nopartof thisbookmaybereproducedinanyform–by photoprinting,microfilm,oranyother means–nortransmittedortranslatedintoa machinelanguagewithoutwrittenpermission fromthepublishers.Registerednames, trademarks,etc.usedinthisbook,evenwhen notspecificallymarkedassuch,arenottobe consideredunprotectedbylaw. PrintISBN:978-3-527-34836-7 ePDFISBN:978-3-527-82974-3 ePubISBN:978-3-527-82973-6 oBookISBN:978-3-527-82972-9 Typesetting Straive,Chennai,India v Contents Preface xi PartI IntroductiontoEPCCIndustry 1 1 Introduction 3 1.1 WhatIsEPCCIndustry 3 1.2 TypesofProjects 4 1.2.1 CostofaProject 5 1.2.2 PurposeofaProject 7 1.2.3 EngineeringNeeds 8 1.2.4 LicensorsNeed 8 1.2.5 ProfitBased 8 1.2.6 ScheduleBased 9 1.3 FunctionofDifferentDisciplines 9 1.4 DifferentPhasesoftheProject 11 1.5 ImportanceofChemicalProcessEngineers 14 1.6 InteractionwithOperatingIndustryorCustomers 15 1.7 InteractionwithVendors 15 1.8 WorksharewithMultipleOffices 17 1.8.1 ImportanceofWorkshare 17 1.8.1.1 Low-CostServices 17 1.8.1.2 LaborShortages 18 1.8.1.3 LeveltheWorkload 18 1.8.1.4 TimeDifferencesinCountries 18 1.8.2 TypesofWorkshares 19 1.8.2.1 WorksharewithanIndividual 19 1.8.2.2 WorkshareaPieceofaProject 19 1.8.2.3 WorksharePartoftheEngineeringTeam 19 vi Contents PartII RolesofChemicalEngineersinDifferentPhasesof theProject 21 2 Phase1(ScopePlanning) 23 2.1 PerformFeasibilityStudies 23 2.1.1 StudyTypes 23 2.1.2 StudyDuration 24 2.2 InteractionwithCustomer,Recommendations,andMeetings 24 2.3 PreparationofPreliminaryScopeReports 25 2.3.1 AssumptionsRequired 25 2.3.2 BasisofDesignDocument 26 2.3.2.1 Contents 26 2.3.2.2 ComparisonofStudyReportwiththeDesignBasisDocument 26 2.3.2.3 BasisoftheEquipment 26 2.3.2.4 ReportFormat 27 2.3.2.5 StudyReportTracking 27 2.4 TechnologySelection 28 2.4.1 TechnologyOptions 28 2.4.2 MeetingBetweenCustomerandEPCC 28 2.4.3 InitiateaStudyContractwithTechnologyCompanies 28 2.4.4 ReviewReportfromTechnologyCompanies 29 2.4.5 CustomerandEPCCMakeaTechnologySelection 30 2.4.6 TechnologySelectionBasedonOtherCriteria 30 3 Phase2(ScopeDefinition) 31 3.1 DevelopaBlock-FlowDiagram 31 3.1.1 WhatIsaBlock-FlowDiagram(BFD) 31 3.1.2 InformationNeededtoDevelopaBFD 31 3.1.3 UtilityBlock-FlowDiagrams 31 3.1.4 Examples 31 3.1.5 UsesofBFDandUBFDs 31 3.2 DevelopaProcess-FlowDiagram 32 3.2.1 WhatIsProcess-FlowDiagram 32 3.2.2 InformationNeededtoDevelopaPFD 33 3.2.3 UtilityFlowDiagrams 35 3.2.4 Example 35 3.2.5 UsesofPFDandUFD 35 3.2.6 DistinguishingNewScopefromExisting 35 3.2.7 RevisionstothePFDsandUFDs 36 3.2.8 TitleblockforthePFD 36 3.3 PrepareIFEQualityP&IDs 36 3.3.1 IFEQualityP&IDs 36 3.3.2 UsesofIFEP&IDs 37 3.3.2.1 GeneralUses 37 3.3.2.2 EstimatingUsesforPhase2Estimate 37 Contents vii 3.3.2.3 ReviewswiththeCustomer 37 3.3.3 ExampleofaP&ID 38 3.4 IdentifyMajorPiecesofEquipment,Instruments,andElectrical 38 3.4.1 IdentificationofMajorPiecesofEquipment 38 3.4.2 ControlsandElectricalEstimate 39 3.4.3 MechanicalEngineeringEstimate 39 3.5 EstimatePreliminarySizingofMajorEquipmentandInstruments 40 3.5.1 PreliminarySizingofMajorEquipment 40 3.5.2 InstrumentSizing 41 3.5.3 EstimationofElectricalLoadsBasedonPreliminaryHorsepower 41 3.6 MetallurgySelectionofMajorEquipment 42 3.6.1 ProvidePreliminaryInformationontheStream 42 3.6.2 SpecialConsiderationfortheMetallurgy 43 3.6.3 MostoftheServicesinRefineryAreCarbonSteel 43 3.6.4 ImportanceofaMetallurgy 44 3.7 CompleteSimulationsforDifferentCasesandPrepareIFEQuality HMB 45 3.8 CompleteStudies 47 3.9 PreliminaryEstimateofUtilitySummary 47 3.9.1 IntroductiontoUtilitySummary 47 3.9.2 UseofUtilitySummaryandValuePlusSuggestions 47 3.10 ParticipationinLOPA 49 3.10.1 WhatIsLOPA 49 3.10.2 FormatofLOPA 49 3.10.3 LOPATeam 49 3.10.4 DifferenceBetweenLOPAandHAZOP 49 3.11 PrepareIFEQualityDesignBasis 50 4 Phase3(ScopeDevelopment) 51 4.1 PerformDetailedHydraulics 51 4.1.1 WhatIsDetailedHydraulics 51 4.1.2 ExamplesofCriticalityofHydraulics 52 4.1.3 ImportanceofDesignSafetyMargin 52 4.1.4 BatteryLimitTableCoupledwithHydraulics 53 4.1.5 LineSizingCriteriaforHydraulics 54 4.2 DetailDesignofOtherEquipment 54 4.2.1 HeatExchangers 54 4.2.2 Vessels 56 4.2.3 Columns 56 4.3 InputtoLineListandtheProcess 57 4.4 CreateChangeOrdersandReportAnyChangestoProject 63 4.5 ProcessDataforInlineInstruments 64 4.5.1 InputtoInlineInstrumentDatasheets 64 4.5.2 HowProcessEngineersGettheData 64 4.5.3 HowControlSystemUsetheData 65 viii Contents 4.5.4 DataCheckingandWorkProcess 65 4.6 PreparePreliminarySafetyValveEvaluations 66 4.7 PrepareandIssueEquipmentDatasheets 68 4.8 CommunicationwithOtherDisciplines,Projects,andtheCustomer 70 4.9 ParticipateinHAZOP 70 4.10 FollowUpandImplementationofHAZOPItems 71 4.11 IssueandPrepareIFR/IFH/IFA/IFDQualityP&IDs/PFDs/MSDs (IncludingTie-in/DemoP&IDs) 72 4.12 CompleteandLeadLine-by-LineReviewsofP&IDs 73 4.13 PrepareIFDQualityDesignBasis 74 4.14 IssueIFDHMBs 74 4.15 UtilitySummaryIFD 75 4.16 PrepareDPDTDiagrams 75 4.17 PrepareMaterialSelectionDiagram 76 4.18 DraftingoftheDrawingsandBackchecking 77 4.19 Inputto30%ModelReviewsandPlotPlanDevelopment 79 4.20 InputtoCostEstimate 80 4.21 BudgetEstimate,Schedule,andStaffingPlan 80 4.21.1 InteractiveSchedulePlanningMeetings 80 4.21.2 BudgetPreparation 81 4.21.3 ScheduleandDates 81 4.21.4 StaffingPlan 81 4.21.5 ProjectStatusProgressandTracking 86 4.22 LeadWorkshareMeetings 87 4.23 InputtoInternalMeetingswithProjectandDisciplineTeams 88 4.24 PlantVisits 89 4.25 InputtoPreparationofDemolitionandTie-inP&IDs 89 4.25.1 Tie-inP&IDs 89 4.25.2 DemoP&IDs 89 4.26 PreparationofPipeServiceIndex 90 4.27 ProcessAudit 91 5 Phase4(DetailedDesign) 95 5.1 ParticipateintheFinalHAZOP 95 5.2 HAZOPActionItemCloseoutandHoldItems 95 5.3 ProjectSupportasNeeded 96 5.4 ProvideOfflineInstrumentData 96 5.5 SquadCheckofProcessandVendorData 98 5.6 FinalizeSafetyValvesDesignandIssueIFDDatasheets 99 5.7 CloseoutofDocuments 101 5.8 Inputto60%and90%ModelReviews 101 5.9 LeadWorkshareMeeting 102 5.10 IFCandIFC–RP&IDs 102 5.11 LineListUpdatesandInputtoNewLines 103 5.12 LeadingMOCMeetings 103