EPC
EPC EPC EPC
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EPC Projects Prepared By:Bahmanzangi
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EPC Projects Prepared By:Bahmanzangi
Package Design & Build Turnkey
Project Management
EPCM
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Finance, Design, Build
Build, Operate & Transfer or BOT Build, Own & Operate or BOO Build, Own, Operate & Transfer or BOOT Build, Lease & Transfer or BLT
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EPC
EPC
Engineering
Procurement
Construction
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EPC
EPC
Conceptual Design Basic Design Front-End Detail Design Procurement Installation Construction Commissioning Operation Pre-commissioning
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EPC
Project Definition (by Owner or Client) Feasibility Study (Tech. & Com.)
Engineering
Conceptual Design Basic Design (&FEED) Procurement
Material requisition Procurement
Detail Design
Construction
Delivery & Inspection
Construction Installation
Pre-commissioning
Commissioning Operation
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Process Department
Process Department
Process Utility Safety
Process Department
Process is the First Department that the Projects will be started with. The Best Process Skim Will be Designed by Process.
Feed
Process
Product
Scope of Services
Feasibility Study Conceptual Design Basic Engineering Design Front End Engineering Design (FEED) Detail Engineering Procurement Services Proposal Preparation for E,EP,EPC Projects ..
Activities List
Part I: Engineering
Philosophies
Process Basis of Design Process Sizing Criteria Utility Design Philosophy Operating and Control Philosophies .
Activities List
Part I: Engineering
Philosophies Process Simulation
Activities List
Part I: Engineering
Philosophies Process Simulation
Design Softwares
Activities List
Part I: Engineering
Philosophies Process Simulation
Design Softwares
HYSYS
Activities List
Part I: Engineering
Philosophies Process Simulation
Design Softwares
HYSYS Provision ASPEN+
Activities List
Part I: Engineering
Philosophies Process Simulation
Design Softwares
HYSYS Provision ASPEN+
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Activities List
Part I: Engineering
Philosophies Process Simulation Heat and Material Balance Table Drawings
Process Flow Diagram (PFD) Utility Flow Diagram (UFD) Piping and Instrument Diagram (P&ID) Block Flow Diagram .
Activities List
Part I: Engineering
Philosophies Process Simulation Heat and Material Balance Table Drawings Process Data Sheets for Equipments and Packages
Process Process Process Process .
Data Data Data Data
sheet for pump Sheet for column sheet for air cooler sheet for storage tank
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Activities List
Part I: Engineering
Philosophies Process Simulation Heat and Material Balance Table Drawings Process Data Sheets for Equipments and Packages Process Calculation
Activities List
Part I: Engineering
Philosophies Process Simulation Heat and Material Balance Table Drawings Process Data Sheets for Equipments and Packages Process Calculation
Line Sizing Calculation Vessel Sizing Calculation Pump Sizing Calculation Flare Calculation .
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Activities List
Part I: Engineering
Philosophies Process Simulation Heat and Material Balance Table Drawings Process Data Sheets for Equipments and Packages Process Calculation Lists
Activities List
Part I: Engineering
Philosophies Process Simulation Heat and Material Balance Table Drawings Process Data Sheets for Equipments and Packages Process Calculation Lists
Equipment List Utility Summary .
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Activities List
Part I: Engineering
Philosophies Process Simulation Heat and Material Balance Table Drawings Process Data Sheets for Equipments and Packages Process Calculation Lists
Equipment List Utility Summary .
Activities List
Part I: Engineering
Philosophies Process Simulation Heat and Material Balance Table Drawings Process Data Sheets for Equipments and Packages Process Calculation Lists Operating Manual
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Activities List
Part II: Procurement Services
Fill Out TBA Form According to Process Information Clarification Meeting with Vendors Vendor Documents Check
Interfaces with Other Disciplines
Piping Mechanical Machinery Instrument Electrical Civil
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Interfaces Inside Process Department
Process PFD
A
Process
Equipment list
A
Heat & material balance table
A
Operating manual
A
Comment on operating manual
Safety
Interfaces with Other Disciplines
Process PFD A Equipment Input to list A piping data sheets
B A
Process
Process P&ID
A
PDMS model review
B
Input to line list
B A
A B
PDMS modeling
Piping data sheets
Comment on P&ID
Piping
Line list
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Interfaces with Other Disciplines
Process
Equipment list A Process data sheets for equipments and packages
A
Comment on vendor documents
B
Vendor Documents
Mechanic/ Machinery
Interfaces with Other Disciplines
Equipment list A Input to instrument Process data sheets B Operating & control Process philosophy A P&ID Input to cause & effect
B A A
Comment on P&ID
Instrument data sheets
Cause & effect
Instrument
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Interfaces with Other Disciplines
Process
Utility summary
A
Equipment list
A
Electrical
Interfaces with Other Disciplines
Process
Safety Drawings Plot Plan
CIVIL
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PIPING
Piping
Piping Department:
Material Design Stress and Support 3D Model Data Center
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ISSUED DOCUMENTS BY MATERIAL SECTION
1. 2. 3. 4. 5. 6. Piping Material Specification (Classification) Line Lists Specifications and Data sheets Piping Welding Specification Welding Procedure Specification Painting, Coating & Wrapping and Insulation Specification 7. Piping Material Take Off (B.O.M) 8. Material Requisition 9. Technical Bid Analysis 10.P & ID Mechanization (Piping-Process)
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Piping
Design
ISSUED DOCUMENTS BY DESIGN SECTION 1.Overall Project Plot Plan 2.General Plot Plan 3.Key Plan 4.Unit Plot Plan 5.Assemble Drawing 6.Nozzle Orientation 7.Single Line Pipe Rack 8.Piping Design Criteria 9.Isometric Drawing 10.Piping Arrangement
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Piping
3D MODEL DESIGN
GENERAL PLOT PLAN
Equipment Modeling
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Piping
Stress & Support
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ISSUED DOCUMENTS BY STRESS & SUPPORT
1.Flexibility Analysis Specification 2.Standard Support 3.Stress Calculation 4.Clip & Bracket on Tower and Tank 5.Special Pipe Support Drawing 6.Load of Pipe Rack 7.Support List 8.Support Material Take Off 9.Material List for Spring Support 10.Material Requisition
Piping
3D Model Data Center
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Piping PDMS
( Plant Design Management System )
This software is an advanced and intelligent software which is used in design of the plant systems. In this software, lines and equipments,structure are shown in three dimensional pictures and designer can see the actual design which has been made, contemporary. So,the probability of error and mistake decreases.
Piping
Major Activities In 3DM.D.C Section: 1.Catalogue(Material) 2.Draft Administration(Design) 3.Isometrics Administration(Design)
4.Reporting(Material-Support-Design)
5.3D Model R&D(Material-Support-
Design) 6.Model Review
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Piping
HOME
EXIT
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Pipe Supports
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Civil, Structure, Architecture, HVAC Department
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Civil Department
Civil
Site preparation Underground
Pit
Valve pit Equipment pit Process pit
Civil Department
Civil
Site preparation Underground
Pit Cable trench Drainage pipe and channels Duct bank Man hole & catch basin
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Civil Department
Civil
Site preparation Underground Foundations
Civil Department
Civil Structure
Steel Concrete Building
Blast proof Non- blast proof
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Civil Department
Civil Structure HVAC Architecture
Building
Industrial
Blast proof Non blast proof
Civil Department
Civil Structure HVAC Architecture
Building
Industrial Non-industrial
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Civil Department
Civil Structure HVAC Architecture MTO and Cost Estimation
Preparing MTO & tender documents Marketing and proposal
Civil Department
Civil Structure HVAC Architecture MTO and Cost Estimation Field Engineering Services
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Activities List
Part I: Engineering
Activities List Part I: Engineering
Specifications Data sheet (HVAC) Calculation (civil, structure,)
Loading Analysis
Design softwares STAAD PRO, STAAD III SAFE SAP 2000 ETABS 2000
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Activities List
Part I: Engineering
Specifications Data sheet (HVAC) Calculation (civil, structure,)
Loading Analysis Design
Activities List
Part I: Engineering
Specifications Data sheet (HVAC) Calculation (civil, structure,)
Loading Analysis Design Calculation note Drawing (Auto cad)
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Activities List
Part I: Engineering
Specifications Data sheet (HVAC) Calculation (civil, structure,) Drawings (AutoCAD)
Layout (architecture, HVAC, civil) Detail drawings (architecture, civil, structure)
Activities List
Part I: Engineering
Specifications Data sheet (HVAC) Calculation (civil, structure,) Drawings (AutoCAD) PDMS Modeling X steel
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Activities List
Part II: Procurement Services
Material take off Tender documents (civil work, piling) Installation tender Inquiry documents (steel structure, bolt and nut, anchor bolt) Technical bid analysis Vendor documents review
Activities List
Part III: Other Discipline Document Review Plot plan Equipment list Single line for pipe racks Loading for pipe racks Mechanical drawing (machinery, fix) Instrument drawing Electrical drawing Safety drawings Telecommunication drawings PDMS model review
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Interfaces with Other Disciplines
Piping Mechanical Machinery Instrument Electrical Safety Telecommunication
Interfaces with Other Disciplines
Civil
Civil underground
Pipe rack design & PDMS modeling
PDMS modeling & model review
PDMS modeling & model review
Piping underground Single line of pipe racks & loading
Piping
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Interfaces with Other Disciplines
Civil
Foundation design & PDMS modeling
Inquiry for anchor bolts
(including loads, skid, anchor bolt arrangement,)
Mechanical drawing
Mechanic/ Machinery
Interfaces with Other Disciplines
Civil
Tray route design & PDMS model
Trench route design & PDMS model
Design of control rooms architectural layout Main cable tray route Main cable trench route Control rooms arrangement layout & opening
Instrument
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Interfaces with Other Disciplines
Consider in architectural drawing
Civil
Trench rout design & PDMS modeling
Tray route design & PDMS model Lighting layout
Design of substations architectural layout
Main cable trench route
Design & consider in Main cable tray route PDMS model & drawings Substation arrangement layout and openings
Earth pit & Conduit
Electrical
Interfaces with Other Disciplines
Civil
PDMS model review
Design of CO2 rooms architectural layout
Check detail
Hose box in site
CO2 room arrangement and location
Hose box installation detail
Safety
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Interfaces with Other Disciplines
Civil
Designing structure and foundation
Consider in architectural drawing
Telecommunication equipment
Telecommunication arrangement layout & opening
Telecommunication
Electrical & Telecommunication
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Content
Content Organization Chart Activities Interface With Other Department
Activities list
Part 1 : Engineering
Basic Electrical Design philosophy Consumer Lists Calculation Notes Specifications Single Line Diagrams Arrangement & Routing
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Activities list
Basic Detail Calculation Notes Data Sheets Drawings Electrical Equipment Arrangement Installation Details Material Take Off
Part 1 : Engineering
Activities list
Part 2 : Procurement services
Material Requisition Technical Bid Analysis Vendor Document Checking Factory Acceptance Test
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Activities list
Part 3 : Proposals
ITB Review M.T.O. Man hour Estimation
Interfaces with the other disciplines
Process/Safety Civil Piping Instrument Machinery & Mechanical
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Interface with Process/Safety
Process/Safety
Design Safety Philosophy Hazard Study Report Fire Fighting And Safety Process Flow Diagram Shutdown Philosophy Piping & Instrumentation Diagram Electrical Load List Hazardous Materials Schedule
Electrical & Telecom.
Hazardous Area Classification
Interface with Piping
Piping
Plot Plan and Plant Layout Design Piping Design / Model
Electrical & Telecom.
Hazardous Area Classification Main Cable Routing Power And Earthing Layout
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Interface with Civil Civil/Structure/HVAC Electrical & Telecom.
HVAC D&ID Platform and Ladder Drawings Equipment Structure Layout Soil Investigation Report Building GAs Building Struct. GAs Hazardous Area Classification Main Cable Routing Substation Power And Earthing Layouts
Interface with Machinery Machinery&Mechanical Electrical & Telecom.
Data sheets/Specifications Machine/package Vendor Data Hazardous Area
Classification
Electrical Power Required Protections Load List Motor Data Junction box location Cabling
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Interface with Instrument Instrument
Power Consumption MCC Interlock Checking PMS Display Implement In central Control system Instrument Cable Route External Power Requirement Electrical Heat Tracing Requirement
Electrical & Telecom.
Hazardous Area Classification UPS Sizing Load List MCC Circuit Diagram Power Cable Route Power Junction Box Electrical Heat Tracing
Mechanical Department
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Activities
Activities Related to Marketing Projects Basic/Detail Engineering and Engineering Procurement Services (Main Activity of Mech. Dep.) INSPECTION ISO Related Activities Holding Training Courses
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Mechanical Department
Mechanical Department is involved with 4 main groups of fixed equipment: Pressure Vessels Storage Tanks Silos Heat Exchangers (Including Shell &Tube H.E., Air Coolers, Plate Type, Spiral,)
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Mechanical Fixed Equipment
Pressure Vessels: Drums:
- Stainless Steel Drums - Carbon Steel Drums - Special Materials Drums Supply of All Special internals by others
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Pressure Vessels: Reactors: - Stainless Steel - Carbon Steel - Special Materials Supply of All Special internals by others
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Mechanical Fixed Equipment
Pressure Vessels: Columns/Towers:
Supply of column internals by others
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Spherical Storage Tank
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Shell & Tube Heat Exchangers
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Different Types of Heat Exchangers
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Kettle Type H.Exchangers
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Plate Type H.Exchangers
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Induced Air Coolers
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Forced Air Coolers
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. . () . . ( )Shut Down . . .
( )
()
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Storage Tanks
Storage Tanks are usually classified according to their design code as follows: 1- API-650 Tanks 1.1- Floating Roof (Internal or External Floating Roof) 1.2- Fixed Roof (Supported Roofs and Self-Supported Roofs) 2- API-620 Tanks 2.1- Single Wall (Supported Roofs and Self-Supported Roofs) 2.2- Double Wall 3- BS-7777 Tanks 3.1- Single Containment 3.2- Double Containment 3.3- Full Containment
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Cone Roof Storage Tanks
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Dome Roof Storage Tank
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Sealing of Floating Roof Tank
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Seite 1
Liquefied gases with evaporating temperatures*
I-Butane i-Butane -11 C
Vinyl chloride Ammonia Chlorine Propane Propylene LPG Ethane Ethylene Methane
-13 C -33 C -34 C -42 C -47 C
-11 to -47 C -88 C -103 C -163 C
* at ambient pressure
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Single containment
Suspended deck insulation
Shell insulation
PUR
A single containment is a single wall tank and has to be surrounded by a low bund wall (retaining wall) to contain any liquid leakage
Retaining wall
Bottom insulation
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Giese
Double containment
Shell insulation Inner cup LT- steel Outer tank LT- steel
The inner cup and the outer tank have been designed to store the cold liquid. In the event of failure of the inner cup, the liquid will be kept in the outer tank. The outer tank will also accommodate the insulation. In the case of leakage the outer tank could not keep the gas product when being heated by the contact with the outer tank.
- 104 C
Bottom insulation
Stored liquid: Ethylene at -104 C
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Full containment
Suspended deck insulation
Shell insulation Tank shell LT-Steel Cup shell LT-Steel
With regard to the cup in tank system a non-polluting storage tank with insulated collecting space has been developed. ln the event of failure of the inner cup, the outer tank can accommodate the product so that no liquid or gaseous product comes into contact with the atmosphere.
Stored liquid: Toxic liquids like ammonia at -33 C
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Silos
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Silos
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Silos and Hoppers
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Silos Vendor selection
Manufacturer with Reliable Technology for
Aluminum Equipments
Zeppelin Ellimetal
Germany Belgium
Jansens & Dieperink
Netherland
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Prefabricated Materials
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Fabrication
85t Crane
250t Crane
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Site Fabrication
Time Duration for Site Fabrication
Plan 9 Months (based on Initial Plan with Foreign Welders) Actual 12 Months (with employing Iranian Welders and site unexpected events)
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SITE TRANSPORTATION
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Interfaces Between Mechanical Eng. Dep. and Other Disciplines
Mechanical Dep. Mechanical Spec.s, Equipment Weights, Mechanical DWG/ Data Sheets, Vendor Proposal, Vendor Documents
Foundation Plan, Steel Structure/Racks/Shelters, Equipment/ Equipment Foundation Civil / Structure / Building
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Interfaces Between Mechanical Eng. Dep. and Other Disciplines
Mechanical Dep.
Mechanical Spec.s, Mechanical DWG/ Data Sheets, Material Requisition Vendor Proposal, Vendor Documents
Design Spec., Data Sheet, Typical Detail Drawing, Nozzle Information Drawing, Control System Block Diag., Fire&Gas Detection System Diag.
Instrument
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Interfaces Between Mechanical Eng. Dep. and Other Disciplines
Mechanical Dep. Mechanical Spec.s, Mechanical DWG/ Data Sheets, Vendor Documents
Data Sheets, Vendor Drawing Machinery
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Interfaces Between Mechanical Eng. Dep. and Other Disciplines
Mechanical Dep. Mechanical Spec.s, Mechanical DWG/ Data Sheets, Vendor Proposal, Vendor Documents
Unit Plot Plan, Steam Tracing Schedule, Ladder&Platform, Pipe Support List, Nozzle Orientation Piping
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Interfaces Between Mechanical Eng. Dep. and Other Disciplines
Mechanical Dep. Mechanical Spec.s, Equipment Weights, Mechanical DWG/ Data Sheets, Material Requisition, Vendor Proposal, Vendor Document
PFD, P&ID, Process Data Sheets, Process Design Basis, UFD, Safety Layouts & Drawing, Passive Fire Protection, Foam System P&ID, Fire Water P&ID
Process and Safety
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Interfaces Between Mechanical Eng. Dep. and Other Disciplines
Mechanical Dep.
Mechanical Spec.s, Mechanical DWG/ Data Sheets, Material Requisition, Vendor Proposal, Vendor Documents
Hazardous Area Classification, Grounding Plan, Cathodic Protection System, Electrical Heat Tracing System, Overall Hazard Area Clarification
Electrical
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PROCESS & SAFETY
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PROCESS & SAFETY
CIVIL & STRUCTURE
PROCESS & SAFETY
CIVIL & STRUCTURE MACHINERY
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PROCESS & SAFETY
CIVIL & STRUCTURE MACHINERY MECHANICAL
PROCESS & SAFETY
CIVIL & STRUCTURE MACHINERY
ELECTRICAL
MECHANICAL
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PROCESS & SAFETY
PIPING
CIVIL & STRUCTURE MACHINERY
ELECTRICAL
MECHANICAL
PROCESS & SAFETY
INSTRUMENT
PIPING
CIVIL & STRUCTURE MACHINERY
ELECTRICAL
MECHANICAL
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