Episode 30 : Project Execution ( Part 1 )

SAJJAD KHUDHUR ABBAS
Ceo , Founder & Head of SHacademy
Chemical Engineering , Al-Muthanna University, Iraq
Oil & Gas Safety and Health Professional – OSHACADEMY
Trainer of Trainers (TOT) - Canadian Center of Human
Development
Episode 30 : Project
Execution ( Part 1 )

4.1.2 Systematics
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 to
documents
made easier
shall be
for the
employees involved by
applying directory
structure for computer
files or a systematics
for the description of
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 post
should 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 Nam
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 as
COMPANYNAME-001B.DOC

Revision service
Modifications of already existing project documents
The original draft usually gets the revision no. 0 with
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 management has
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

Time Schedule for Component Procurement
KKKK6024

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 units
Calculation of
procedural basic
operation
mainly in
chemical &
thermal process
engineering
Software in
E/MC‐
technology
Types 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 Dynamics
interference 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 general
ii) the neighbors of the plant to be erected in particular
iii) employees of the operating company – as well as the issues of the plant
operator are examined
iv ) contact the relevant authorities of the respective country in due time
v) 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 piping
dimensions & piping routes
 Some plant manufacturers decide to simply “assess” the pumps to
avoid 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 and
parallel 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‐divided into components or systems to ensure
a certain transparency of the total plant system
Process & Instrumentation Diagram

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Episode 30 : Project Execution ( Part 1 )

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Episode 30 : Project Execution ( Part 1 )