5.2.

5 Construction Phase
The construction phase of a project usual starts midway through the
detailed design phase, and it starts with the civil and structural
engineering disciplines. The major activities during this phase are
•
Site clearance (civil engineers).
•
Roads (civil engineers).
•
Trenching for underground piping (civil engineers).
•
Foundations for major equipment (civil engineers).
•
Pipe racks and pipe tracks (structural engineers).
The piping content for the construction phase generally starts
approximately 75% through the detail design phase, after the P&IDs
are issued for construction. The 3D modeling is in progress and 30%,
60%, and 90% of the model reviews should be completed and
the extraction of the isometric IFC commenced.
The fabrication of piping spool usually takes place at the job site or a
location very close to it, to reduce the transportation costs
and simplify the logistics. IFC isometrics are issued by the EPC
contractor responsible for the detailed design and sent to the
piping fabricator, who is often a subcontractor.
Advances in information technology mean that these production
isometrics can be sent electronically to the fabrication shop, where
they can be converted into spool isometrics. The fabrication site will
have been receiving piping material for several months, and it is
essential that there is harmony between the delivery of material,
delivery of isometrics, and the construction sequence, because
•
It is pointless to issue isometrics if the material has not arrived.
•
It is pointless if the material has arrived and the fabrication shop
is waiting for the isometric to be issued.
Assume all the piping material and the isometrics have arrived and the
spool is fabricated but it is not in line with the construction sequence.
For a certain period this can be acceptable, because spools can be
stored for a period of time, but there is a limit to the space available.
The ideal situation is that, once a spool has been fabricated and
passes all the nondestructive examination tests, it should be
transported to site immediately and installed as quickly as possible, in
line with the construction sequence.
As the 3D model approaches 100%, the isometric extraction continues
until the project is complete.
Hydrotesting the erected pipe usually follows the construction
sequence. As the piping system becomes complete, it can be
subjected to a hydrotest in accordance with the design code for the
project. Normally, this is 1.5 times the pressure class rating at ambient
for a hydrotest and 1.1 for a pneumatic test. The air test is lower,
because of the high danger level with the stored energy of
the compressed air contained within the piping system.
Piping systems in a specific unit or area are tested until all the
systems in the unit or area are mechanically complete and the project
can move to the commissioning phase. Mechanical completion occurs
when
•
All design and engineering has been completed.
•
All equipment has been completed in accordance with the IFC
drawings, specifications, applicable codes, and regulations.
•
All instruments have been installed.
•
All factory acceptance tests and all other testing and inspection
activities have been completed.
•
The EPC contractor has obtained all approvals for which it is
responsible.
•
 All hazardous operations checks have been completed.
•
Operating procedures and maintenance procedures are on site.
•
Third-party, regulatory, and company approval have been
obtained and confirmation documentation provided to the
company.
By the middle of the construction phase, the detailed design
group will be gradually reduced in size, and it is not uncommon
for certain key personnel to be transferred to the site as field
piping engineers, so that they can use their experience from
the detailed design stage to answer site queries.
For the piping group, the major deliverables during this phase are as
follows. The piping material engineering group prepares
•
Review and approval of vendor documents.
•
Review and approval of deviations from manufacturers.
•
Resolution of site material queries.
The piping design group prepares a piping CAD 3D model and the
piping isometrics (IFC). The piping stress group prepares a Piping
flexibility analysis for critical lines (IFC) and the stress isometrics (IFC)
and assembles stress packs (IFC). The piping material control
groupprepares top-up material takeoffs for requisitions (IFC) and the
control reports of piping materials delivered to the site (IFC).