SAJJAD KHUDHUR ABBASCeo , Founder & Head of SHacademyChemical Engineering , Al-Muthanna University, IraqOil & Gas Safety and Health Professional – OSHACADEMYTrainer of Trainers (TOT) - Canadian Center of Human Development

Episode 30 : Project Execution ( Part 1 )

4.1.2Systematics

Being used to master the multitude of documents or activities mentioned in Project structures

3 examples will describe the application of these systematics: Project manual Revision service Correspondence system

Project Manual

•To guarantee professional project planning and execution.

•all activities required for execution within the framework of a project& documentation to be prepared, are arranged according to an in - house system.

•planning packages not feasible for the present project have to be deleted

•filing of and access todocuments madeeasier

shall befortheemployees involved by

applyingdirectory structure for computer files or a systematics forthe descriptionof files.

Correspondence system• Numerous numbers of letters, facsimiles, minutes of

meeting, memoranda are exchanged between employer, contractor and subcontractors.

• Email correspondence has increased but traditional postshould be retained as written documentation.

• To guarantee clarity and easy access:incoming or outgoing letter will consecutively

numbered.document number linked with a filing system or the

systematics of the project manual.

Example:• Complete outgoing correspondence will be filed in EDP-register called “Project Name

Correspondence”.

• This register contain 1 sub-register (company’s name) for each company.

• This sub-register contains 3 further sub-registers:Letters (denoted as L)Facsimiles (denoted as F)Minutes of meeting (denoted as M)

• Registers individual documents may named asCOMPANYNAME-001B.DOC

Revision service

Modifications of already existing project documents

The original draft usually gets the revision no. 0with each revision numbers are counted up.

The revision line of the respective document indicates which revision is concerned.

The meticulous tracing of modifications and thus of revisions is of utmost importance for the execution of projects

Example

•Sub – contractor informs the project engineer it would be better to mount the brackets of the heat exchanger 15 cm higher due to processing reasons.

•Sub - contractor changes the production drawing and sends it to the plant manufacturer as revision no.1 after the project engineer gives his approval.

•If the plant manufacturer forgets to furnish the layout planner with a copy, design in the system layout will be based on revision 0 of the heat exchanger.

•With the latest revision being unnoticed the assembly will end in disaster.

7

Cost Monitoring

1] Project management is required to prepare a monthly order report :

forecast in which the looming technical, commercial or schedule problems.

2] Cost Calculation:compares the actual costs with the cost objectives of the preliminary costing of the project.Significant deviations: cause the problems like schedule delay, increasing the staff.

3] Claims Management: extra costs will be assessed addendum negotiations on additions, omissions or claims

Continue…

Prepare the order report:•current state of development meetings

regular project

•function control instrument (detect risks)•the conflict situation the project managementhas to cope with becomes clear.

Time Scheduling/Monitoring of Dates

Execution process in plant manufacturing is made up of a large number of individual processes. The beginning of many processes is contingent on previous activities having been completed with a certain result.

During the assembly phase, events are the physical availability of certain equipment and the completion of assembly work. Thus the inevitable chronology of processes is characteristic of the whole process period.

The scheduling of project chronologies and their explicit depiction are essential objectives of time scheduling or workflow scheduling.

Time Scheduling/Monitoring of Dates

Missed deadlines will result in liquidated damages, extended project duration, and directly increase in employment costs.

Gantt Charts are set up to list the activities one below the other, resulting in the period of time required for the completion of the activity from the beginning and the end of this activity.

The relevant EDP ‐ programs are used for setting up time schedules and the planning of resources.

Important Time Schedules

Time Schedules

E/MC ‐ Technology Manufacturing and

assembly of the piping

Assembly work flow

Project planning phase

Detail engineering

Commissioning

Procurement of the components

Erection phase

Framework Time Schedule

Time Schedule for Component Procurement

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Time Schedule for Commissioning

Computers in Plant manufacturing

Office Applications

Basic software of system engineering

Databases retrieved for various process calculations

Spreadsheet analysis program

Used for all kinds of correspondence, integrated index, classification system

CAD/CAE

Project Planning Phase‐ plant concept modeling‐ Arrangement of components in system‐ piping layout‐ cost assessment of piping packages

Execution Phase‐ P&ID‐ layout design‐ piping plans

CAD/CAE linked to component catalogues, 3 ‐dimensional models,

Example: Computational

FEM/Pipe Stress

Analysis

Applied on progress of stress & deformation in branched piping systems

Components disassembled into multitude of small units called finite elements, cover the modeled component like net or skeleton framing

Process Simulation

Used for planning & layout of processes in entire systems / plant unitsCalculation of procedural basic operation mainly in chemical & thermal process engineering

Software in E/MC ‐

technologyTypes of software:‐ Control loop‐ Control technology (provided by supplier of control equipment)‐ Preparation of

continuous function chart

‐ E engineering‐

Others

‐ Databases‐ Documentation

systems‐ Time scheduling‐ maintenance & repair software

Fluid Dynamicsinterference check

•The authority approval provides a secure legal basis for the erection and operation of process plants

•Approval process :i) the legitimate interests of the public – i.e. the public in generalii) the neighbors of the plant to be erected in particulariii) employees of the operating company – as well as the issues of the

plant operator are examinediv ) contact the relevant authorities of the respective country in due timev) commission engineering agencies or a lawyer ’ s office specializing in the

field of authority engineering

•In case a new plant is to be erected and operated, it has to be verified at first if an authority approval will be required. The statutory regulations and conditions may vary considerably subject to the respective country.

APPROVAL PLANNING

Procurement

Initially, component procurement is focused on the components with the longest delivery times.

Longer delivery times is considerably higher procurement costs.

A quotation comparison is necessary to shortlist the subcontractors.

The commercial and technical conditions for the plant manufacturer ’ s order at the subcontractor are also stipulated in the form of a purchasing contract.

The consequences of a subcontractor ’ s delay in delivery will be excessively high costs.

• Long delivery time – have to order in due time.

• In early project phase piping and instrumentation diagrams as well as detailed layout and piping plans – not yet exist.

• To specify the vessel data, following procedure possible:– Number of connecting pipes assessed by PFD or with the first draft of

piping and instrumentation diagram.– Nominal width of connecting pipes assessed – basis of the available

balancing or media data sheets. Doubt case – larger nominal width chosen.

– Connecting pieces for measuring equipment of vessel approximately determined. Normal atmospheric vessel – determined quite easily.

– Other nozzle : manhole, overflow pipe, emptying pipe, connection for sample taking etc.

– All vessel section – additional reserve nozzles (different nominal width)

Vessels

– Position of nozzle – through their function or layout– the contract with the subcontractor – nozzle modifications with

regard to their position are carried out free of charge and that additional nozzles can be mounted up to a certain point in time (e.g. release of production drawings).

• These procedure – at least inquiries to subcontractor in early time

• The strength – related layout and the warranty regarding corrosion, vessels do not require further function guaranties.

Vessels

Pumps may require quite long delivery times‐ designed by using non commercial materials

Detailed calculation of the pressure drop requires the exact pipingdimensions & piping routes

Some plant manufacturers decide to simply “assess” the pumps toavoid this problem.‐ the required pump head will be assessed on the basis of the layout and of the

operating data

Another way of proceeding to avoid the problems:‐ Preparation of P&ID‐ Determination of piping classes‐ Determination of nominal widths & nominal pressures‐ Fitting concept

Pumps

Drawing of P&ID is started immediately after the order placing andparallel to the procurement of the components.

Basic information‐ All appliances and machinery, including motors‐ All pipes or means of transport (conveyor belts)‐ All pipe installations (valves & fittings) and moulded parts (tees)

The database is sub divide‐ d into components or systems to ensurea certain transparency of the total plant system

Process & Instrumentation Diagram

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