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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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EPC Projects Prepared By:Bahmanzangi

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 Projects Prepared By:Bahmanzangi

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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