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Management of Medium-Size /

Revamping Projects
Oil & Gas Downstream Projects
3. Basic Engineering

RC - PR GES - 08170_A_A - Rev.1 - 18/07/2013


FEED Scope and Objectives

 Scope
• Complementary studies, analysis, engineering and design
• Technical optimization of project contents
• Finalize Safety/Health/Environmental Analysis

 Objectives
• Confirm technical scheme selection (including Licensing)
• Develop technical specifications for supplier bidding purposes
• Confirm Budget and Schedule
• Finalize Project Execution Plan
• Compile dossier for:
− Final Investment Decision by Owner
− EPC Contractor Call for Tender

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− Regulatory approval, when applicable

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Typical FEED start checklist

Are the following items complete?

 Preliminary Study (or pre-FEED) report


 Basis of Design
 Statement of Requirements (SOR)
 For Revamped areas:
• Valid documentation on existing facilities
• Accurate description of existing processes and utilities
• Up-to-date layout, plot plan, undergroung routing
 Preliminary Safety Analysis (HAZID, HAZOP) built in the design basis
 Environment Base Line Study, preliminary Environment Impact Assessment
 Owner design standards and rules

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 Owner approved FEED Budget & Schedule

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Specific objectives

 TECHNICAL
• Study in depth the technical solutions of the pre-project for each discipline
• Issue AFD (Approved For Design) drawings (layouts, PID's…) and
specifications
• Prepare technical dossiers for LLI (Long Lead Items) and EPC contract
bidding
• Issue CAPEX cost estimate with the adequate accuracy level (10%)

 CONTRACTS
• Prepare the contractual part of the call for tenders for LLI and EPC
• Issue tenders evaluation procedures for LLI and EPC, and launch calls

 ORGANIZATION
• Finalize Project Execution Plan including:
− Contracting strategy
− Quality Assurance plan

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− HSE Risk Mitigation plan
• Define communication and project control systems
• Finalize Owner organization and project schedule
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Technical package

 The FEED package should be sufficient to start Detail Engineering:


• In-depth studies to support the Safety Analysis (as per corporate
method)
• Environmental Impact Assessment consistent with local
requirements
• Specific studies/deliverables to obtain approval from local
authorities
• Review and integration of Licensor’s Basic Engineering Packages

 Adequate reviews of the FEED package should be performed


• Independent review/audit of the most delicate calculations
• Systematic workshop with Owner/Stakeholders to validate FEED
quality

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• Communication with the site Safety Committee, if appropriate
• Technical package reviewed and approved by the Owner
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FEED
Organization/Management

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PMC role

 Reminder: the Leader of the FEED is the Owner

 Owner may manage and control the Project with its own resources

 If so, a Project Management Consultant will usually provide support:


• Additional Management resources
• Technical skills for verification of Contractor studies
• Assistance for developing the execution strategy (PEP)
• Contracting strategy, tender selection process/criteria
• Internal communication

 Later, the PMC may remain in the Project Team (part-time)


• Auditing
• Ad-hoc technical advice

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• Controls of equipment (quality, delivery schedule) and field works

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Management

Usual Project Management techniques are used, (in particular for Engineering & Project
Control); the following higher level management concerns apply:
 Coordination and communication between Owner & FEED Contractor; participation of
Operations personnel at right times
 Resource planning and qualification (full-time & part-time personnel, experts…)
 Coordination of Licensors (Special Processes) and Consultants for Special Packages
 Project Contractor/Owner Reviews with experts from Contractor /Owner/Partners
 FEED Project Control (cost, schedule & progress, changes management, …): similar as
described for the Concept studies, but the FEED Contractor may use his regular
Engineering Project Controls tools (e.g. Progress system, PRIMAVERA for scheduling).
 Risks & uncertainties identification; track latent defects; do not « fix » too early.
 Ensure FEED quality as basis for the EPC phase
 Well understood Owner decision process and Level of decision Approval

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 Contract based on reimbursable expenses as the scope, in some cases, may not be
sufficiently fixed at the start (e.g.: revamping; projects with novel aspects…)

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Constructability review

Lay-out Constructability Concepts

 Construction and Commissioning Inputs into the Engineering

 Accesses for:
• Contractor personnel (from inside/outside offices, control room)
• Equipment / modules delivery
• Temporary storage of equipment, parts, bulk
• In-situ lifting or rolling
• Equipment dismantling (important for revamping)

 Conflicts created by simultaneous operations (“SIMOPs”)

 Pre-fabrication plans

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 Module fabrication / delivery / integration plan for offshore facilities

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3D models help to check construction feasibility

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3D models help to check construction feasibility

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• An up-to-date 3D model is a useful tool for revamping studies
but
• As-built drawings must always remain the contractual reference
(the model may not be updated with last construction status)
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Procedures

 Appropriate and well-known procedures: a key Management tool

 General Project Management procedures


• List of Project Procedures, Glossary of terms and acronyms
• Guidelines for the Preparation of Project Procedures
• Coordination Procedure (with Owner, Partners, Licensors)
• Document Management and Control
• Preparation of Call For Tenders for
− EPC contract
− Equipment Supplies
− Field work subcontracts

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 For small projects, all of them may be summarized in a single
“FEED coordination procedure” applicable as part of an umbrella
contract
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Procedures

 Engineering
• Equipment, Instrument, Electrical & Piping Lines Numbering
• PFD, P&ID preparation, Drawings numbering and formatting
• Preparation of Project Specifications
 HSEQ
• HSE and Quality Management Plan
• Safety review procedure and applicable tools (HAZID, HAZOP, HAZAN…)
• Constructability review procedure
 Project control
• Cost Estimating, Cost Reporting and Control
• Elaboration, communication, revision of Schedule
• Progress measurement, reporting and control
• Management of change requests

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For a Small Project FEED, the Procedures may be simplified to:
• Management of Engineering
• Project Control (HSE, schedule, quality)
• Cost Estimating, Reporting and Control
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FEED Deliverables

 Statement of Requirements + Execution Plan til S/U (revised)


 Process basis, data sheets, flow diagrams, heat&matl balances
 Job specifications and standard drawings for each discipline
• Vessels (columns, drums, storage tanks)
• Thermal equipment (furnaces, boilers, exchangers)
• Piping networks, key instrumentation, control loops
• Buildings, infrastructure (site study, jetty, roads…)
 Procurement basis (refined)
• Call For Tender documents, Quality Plans, evaluation criteria
• List of acceptable suppliers, short-list, Long Lead Items orders
 Health/Safety/Environmental risk analysis (revised)
Final Cost estimate and EPC schedule, controls structure

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Detailed lists of Deliverables: see Attachment III


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Specific considerations for Revamping projects

 Drawings should include Installation & Dismantling documents

 Indication “ New “, “ Modified “, or “ Dismantled “ should appear

 Drawings for Modified or Dismantled should refer to existing ones

 Systematic field verification of existing documents, even if controlled


• Concrete structures, buildings, internal roads
• Steel structures, racks, underground networks (careful)
• Piping configuration (isometric drawings may have to be re-created)
• Electrical cabinets drawings, cable paths, available power in SS
• DCS loops, synoptics, lists of I/O, process computer interface, alarms
• Sizing of Fire Fighting and Waste Water Treatment facilities

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Detailed lists of Deliverables: see Attachment III

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Definitive Project Planning

The following elements, already previously defined,


will be revised, detailed, re-approved, and frozen:

 Project Execution strategy

 Project Schedule

 Project CAPEX estimate

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Project Execution strategy

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Influencing factors

The following location factors may impact the Project Execution Strategy
 Remoteness and availability of site existing infrastructure (roads, railways,
bridges, prefab areas)
 Transportation logistics (may require special transportation means, sometimes
in harsh climatic conditions and in limited climatic windows)
 Local availability of Construction Contractors and Equipment (if insufficient,
may require workforce from abroad, prefabrication at shop, modularisation)
 Local context may impose the use of local contractors, with insufficient
qualification, leading to stronger QC and field supervision requirements
 Impact of local environment on project scope/risk should be closely examined

• Political climate and foreseable changes, security, visa procedures


• Regulatory requirements (US standards, European-type, other, none…)
• Social situation, role and authority of Trade Unions, of local communities

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• Customs clearance requirements, taxes, currencies, financing/bank concerns
• Religious prevailing rules and off-work periods (e.g “Ramadan”)

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Owner permanent objectives

 Sustainable development
• HSE performance (no personnel/process/environmental accidents)
• Risk management (quality of equipment/works, for long-term
reliability)
• Preserve good relationship with local environment

 Technical objectives
• Delivery in accordance with the FEED or BASIC package
• Unit business performance requirements achieved
• Satisfactory performance during the whole expected project life-
time

 Project cost and schedule

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• Project completed on schedule and within approved budget
• Adequate definition and management of contingencies
• Adequate cost control methods
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Contracting strategy

 The Contracting strategy elaborated by Owner (*), considering:


• Project desired or required schedule, and phasing
• Project resource requirements versus expected availability, particularly
for:
− EPC Contractors
− Fabrication
− Transportation & Installation
− Construction

 Execution Strategy: for overall project optimization (Quality, Cost,


Schedule), the scope may be split into manageable Work Packages
• Each package may have a different contract type
• Medium-size projects: single Work package can be considered
• Revamping projects: single Work package highly advisable (interfaces)

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• Owner keeps overall coordination of interfaces between packages

(*) with FEED Contractor support

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Contracting strategy

 Strategy confirmed after market surveys and pre-qualification requests for:


• EPC contractors
• Fabrication contractors and Construction contractors
• Transportation & Installation contractors
• Early Contracts such as site preparation
 Simplified Contractor bids may be acceptable for medium-size projects, if:
• Pre-commitments are necessary for engineering studies
• Early procurement is justified and approved by Owner (LLI)
 The choice of contracting strategy is crucial for EPC phase:
• Project organization: identification of Company personnel in charge of
each main contract management
• Budget and scheduling: structured according to the split of contracts

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 The contracting strategy has a major impact on project cost and schedule

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Final Project Execution Plan

 Updated from Preliminary stage (based on additional information)


• Executive Summary, Project Summary description
• HSE aspects and Risk analysis (more complex tools)
• Execution concerns and contraint, and plan to resolve them
• Regulatory authorization file (from HSE analysis)
• Final Contracting strategy, EPC contract type proposed

 New elements elaborated during FEED (related to the EPC stage)


• Organisation/roles/responsibilities of Owner and EPC Contractor
• Detailed execution Schedule, unit shutdown and startup plan
• Quality Assurance / Quality Control / Inspection plan
• Involvement of Owner Operations personnel, training, startup

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• Selection criteria for suppliers and subcontractors

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Project EPC schedule

 Project EPC Schedule includes:


• Schedule (at least 2 levels of accuracy)
• Identification of the Critical Path
• S-curves and histograms (from detailed level) allowing progress control
• Estimated man.hours for each activity/task
− Detail Engineering, global and by disciplines
− Field Construction, global and by trade

 Schedule Risk analysis (probabilistic method) describes:


• The highlights of the method used, and the assumptions
• The most likely range of project execution duration
• The probability of the project going beyond this duration
• Proposed actions and controls to reduce this probability

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 Schedule may not be that critical for all medium-size projects (value ?)

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Project CAPEX estimate

 CAPEX estimate is required to support the Project Approval by Owner


 CAPEX estimate should be prepared according to Owner WBS/OBS
 For smooth approval, CAPEX accuracy should be around +/- 10% to 15%
 CAPEX remains an estimate, based on quantitative information:
• Manhours and rates for design services
• Equipment list and budget
• MTO/BOQ Quantities x Unit Costs for bulk material
• Construction cost rates x construction mhrs
 Contingency, Risks and Profit factor is added on top of the cost estimate
 Probabilistic tools can help quantifying the risk of cost overrun
 CAPEX estimate memorandum summarizes:
• underlying assumptions (consistent with PEP)
• estimating methodology, sources of data, tools used

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• uncertainties, risks and proposed action to mitigate the risks

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Project CAPEX estimate
Methods (Engineering, Equipment)

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Basic engineering or FEED

Key points to keep in mind

 Applicable standards clearly identified, deviations approved by Owner


 Long Lead Items and Licensor packages should be identified
 FEED consistent with local regulatory requirements (studies conducted)
 Availability and qualification of local workforce to be seriously addressed
 Project schedule includes assumptions, critical path, schedule risk analysis
 CAPEX estimate with 15% accuracy required for project final approval
 CAPEX estimate should be based on quantitative info, not only ratios
 Engineering contracts to perform FEED are typically of reimbursable type
 Most often, final Project Approval is taken right after FEED completion
 Revamping projects have higher risk of cost/schedule overrun
 Revamping: involving Owner Operations / Technology personnel is critical

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ATTACHMENTS
I. FEED contract types

II. Process Licensors packages

III. Detailed FEED Deliverables lists

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ATTACHMENT I
FEED contract types

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FEED contract types (pros & cons)

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ATTACHMENT II
Process Licensors packages

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Process licensors packages (1/2)

 Process Licensors provide specific Process Packages (usually referred to as


« Basic Engineering Package » in particular technology areas, examples:
• Distillation: EXXON, SHELL, FLUOR, PHILIPS, FOSTER, LUMMUS ...
• Acid Gas Treatment and S removal: IFP, LURGI, KTI, MERICHEM, PROSERNAT, SGSI,
UOP…
• Sulphur Plants: JACOBS, PRITCHARD, LURGI, KTI, UOP…
 In addition, technology is provided together with certain equipment, e.g.
Molecular Sieves
• Heavy Oil Upgrading; heavy cuts (Delayed Coker, Visbreaker): CHEVRON, FWC,
LUMMUS… (x) All Licensors names are in alphabetical order, current readiness to
license to be checked.
• Typically BEP (Basic Engineering Package) include:
− HMBs; PFDs: Major Equipment or Equipment Lists and Specifications; Process
Descriptions; Cause & Effect matrices; Information for special equipment;

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Operations & Start-Up manuals (option) or instructions
− Recommended Plot Plan (option)

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Process licensors packages (2/2)

 It is often required / necessary to compare different processing schemes


including a number of licensed units. Licensors usually provide proposals for
this purpose.
 BEP packages preparation for a new unit or modified unit may take 2/3
months; If possible, BEPs should be prepared or at least launched before FEED
to gain Project time. Licensors BEPs preparation is otherwise a critical element
of the FEED schedule
 BEPs will be reviewed by FEED Contractor / Company in Design Reviews
 Final Process Licensor selection is normally through a formal Tendering
procedure with scope including:
• Supply of License, Proprietary Items if any (« Licensing Agreement »)
• Supply of engineering and assistance services (« Engineering Agreement »
that includes BEP and review (some FEED & EPC deliverables) and
supervision services (as-built construction inspection and start-up & tests

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assistance)

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ATTACHMENT III
Detailed FEED Deliverables lists

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FEED Main deliverables catalogue (technical)
 THERMAL
 GENERAL • Heat Exchangers TEMA data sheet “NDL”
• BEDD (Basic Engineering Design Data)
• Data sheets for Air Coolers (preliminary) “NDL”
• Value Engineering Review report
 EQUIPMENT & TANKS
• Technical scope for EPC CFT
 PROCESS • Job Specifications
• Process Optimisation studies report • Design & construction standards.
• Process Flow Diagrams (PFDs) “ID” • Specifications for equipment “NDL”
• Process Descriptions. “NDL” • Specifications for Packages “NDL”
• Process Equipment Lists. “NDL” • Main/ critical Vessels & Heat Exchangers
• Main Equipment Process data Sheets (EDS) drawings “NDL”
“NDL”
• For LLIs: Requisitions, Mechanical
• P&I Diagrams (PIDs) / Line Lists (Process)
specifications, ITPs, Bid comparisons &
“ID”
recommendations
• PIDs Diagrams (Main Utilities) “ID”
• Preliminary Relief Valves Discharge • Tanks list “NDL”
Summary. “NDL” • LNG & LPG Tanks Specifications “NDL”
• Safety Control System Process Description.  CORROSION / PIPING
“NDL” • Job Specifications.
• Catalysts and Chemicals Specification. “NDL”

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• Design & construction standards.
• Preliminary Utility Balance; Chemicals lists.
• Material Selection Diagrams (MSD) and
“NDL”
Corrosion study “NDL”

Notes for Revamped areas: “ID”: “Installation” & “Dismantling” documents; “NDL”: new/modified/deleted items
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FEED main deliverables catalogue (technical)
 SAFETY & ENVIRONMENT
• Job Specifications.
 PLANT LAY-OUT
• Fire Demand Calculation Notes.
• Site Plan • Fire Fighting and Fire Protection Drawings and
• Overall Plot Plan. Diagrams (principles). (ID)
• Unit Plot Plans (Process, Utilities, Offsites) • Main Equipment Specifications. (NDL)
(ID)
• Hazardous Area Classification Drawings. (ID)
• Flare radiation study • Hazards Register
• Interconnecting drawings (option) (ID) • Consequence Analysis (HAZAN) and/or QRA (x)
• Modules drawings (option) (ID) • HAZOP review report
• Special areas lay-out studies (option) • HAZID review report
• Preliminary MTOs for estimate (ID) • Safety Concept or Safety Case (update)
• Preliminary BOQs for construction • Emission studies
contracts (ID)
• Noise study
• Battery Limits drawings
• EBS(x)
• Tie-ins list (option)

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• EIA(x)
• Piping Classes (NDL) • HSE Plan for EPC phase
(x): may be performed by specialized Consultant
Notes for Revamped areas: “ID”: “Installation” & “Dismantling” documents; “NDL”: new/modified/deleted items
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Example of layout principles

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QRA output: Addition of new facilities in an existing site;
generated Total Risk Contour

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Addition of new facilities in an existing site; generated VCE
Overpressure exceeded with a frequency of 10-4/year

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FEED main deliverables catalogue (technical)
 Civil / buildings
• Job Specifications  Infrastructure
• Design and construction Standards • Sea Water intake / outfall /
• Preliminary Drawings for main pipe- pumping station study (x) (NDL)
racks and structures (ID)
• Modularisation study (option)
• Reclamation over sea study (x)
(option)
• Preliminary Drawings for modules
(option) (ID)
• Drainage study
• U/G networks drawings (ID)
• Foundations preliminary drawings
(revamping)
• Buildings architectural dwgs; finishing
schedules (ID)
• HVAC systems specs, diagrams (ID)
• Geotechnical study (x)
• Bathymetry survey (x), Topography
survey (x), Soils survey (x)

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• Preliminary MTOs, BOQs for estimate
(option) (ID)
(x): may be performed by specialized Consultant
Notes for Revamped areas: “ID”: “Installation” & “Dismantling” documents; “NDL”: new/modified/deleted items
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FEED main deliverables catalogue (technical)

 Electrical  Controls & instrumentation


• Job Specifications • Job Specifications
• Preliminary users list (NDL), • Design Standards and
elec balance Typical Diagrams
• Preliminary calculation • Control Systems
Notes (Load Summary, etc.) Architecture Drawing (ID)
• Single Line Diagrams. (ID) • DCS/ESD/F&G Systems
• Preliminary Substations Specifications. (NDL)
Drawings. (ID) • Preliminary Control Room
• Design Standards and and Instrument Technical
Typical Diagrams Rooms Drawings. (ID)
• Main Equipment Specifications. • Interfaces definition
(NDL) drawings (ID)

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• Preliminary MTOs, BOQs for • Preliminary MTOs, BOQs for
estimate (option) (ID) estimate (option) (ID)
Notes for Revamped areas: “ID”: “Installation” & “Dismantling” documents; “NDL”: new/modified/deleted items
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FEED main deliverables (project planning)

 Construction/Fabrication/ T&I  Commissioning


• Constructability review report • Main operating principles
• Construction requirements (production, utilities, export,
control system, metering)
• Accommodation requirements
• Laboratory and QC
• TCF requirements requirements
• Construction Accommodation
specs and drawings (option) • Staffing (Main organization
chart), Logistic means and
• Construction / Fabrication / T&I Logistic base
Execution & contracting Plans
• Commissioning and Start-up
• Construction raw materials plan
availability study (option)
• Construction Contractors /

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Fabrication Contractors
prequalification / availability
study (option)

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FEED main deliverables catalogue (project planning)

 Quality plan (requirements  Procurement and contracts


for EPC phase (for EPC CFT)
• Tendering Procedures
Project controls
• CFT for EPC Contracts
• WBS / OBS
• CFT for LLIs
• Level II EPC Schedule and
schedule memorandum • CFT for Early Contracts
• CAPEX Estimate (generally
+/- 15%) • Tenders Evaluation Reports

• Project Controls • Procurement requirements


requirements for EPC phase for EPC phase (for EPC CFT)
(for EPC CFT) (Scheduling, (Purchasing, Inspection,
Expediting, Traffic)

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Progress Control, Reporting)
• Approved Vendors list

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