Oil & Gas Plant Construction

Project Execution Plan

Details of how a Gas & Oil Plant is constructed, and how the progress, safety and quality is monitored David H Moloney
and controlled. Also the measures to ensure that the site is environmentally friendly. 4th August 2016

http://www.slideshare.net/DavidHMoloney/oil-gas-plant-construction-project-execution-plan
Brief Description

The purpose of this presentation is to give an understanding of

the Methods, Plant and Sequence to construct a Gas & Oil Plant
.

This presentation can be used to engage Stakeholders and to get

the Site Teams commitment to the programme. Also can be
used for Induction Training and as a way to capture and share
knowledge.

Project Execution Plan (PEP) details how a project will be

executed, monitored and controlled.

High in Educational Value and easily understood. Recommended

for Continuing Professional Development (CPD)

This Video Presentation is innovative and has many beneficial

uses.
Table of Contents
Contents
Earthworks

Earthworks includes Excavation, Trenches, Haulage, Grading Backfilling, Filling & Compaction

Gas Processing Facility

Excavate & Load Tipper Trucks
Trench Excavation with Stepped Faces
Trench Excavation with Battered Faces
Tipper Trucks Unloading
Earthworks
Spreading & Compaction Clay fill
Earthworks
Spreading & Compaction Clay fill
Earthworks
Backfill Trench
Earthworks
Excavate & Load, Cart, Tip & Return

Brief Description 7 minutes

Cycle Time for 7km haulage distance

using an Excavator 45 tonne weight
and Dumper with a 40 tonne capacity,
the cycle time is 34 minutes

7 km

14 minutes 7 km 14 minutes

3 minutes
Earthworks
CABC ( Crushed aggregate base course )

Testing Compaction

Mixing Plant
Site Trial
Earthworks
Mixing CABC
Earthworks
Spreading & Compaction CABC ( Crushed aggregate base course )
Earthworks
Spreading & Compaction CABC ( Crushed aggregate base course )
Earthworks
Spreading & Compaction CABC ( Crushed aggregate base course )
Rock - Excavability

The excavability of rock depends mainly on the rock strength and the layer thickness.
This diagram shows excavation methods for rock of various strengths and thicknesses,
with a free face.

ⓒ David H Moloney
Contents
Insitu Piling Construction - Plant & Methods

Plant & Equipment

Crawler Crane
Piling Hammer
Casing
Piling Rig
Concrete Pump
Concrete Mixer Trucks
Tremie Pipe
Reinforcement Cage

3D image to show Plant.

For construction details see my YouTube Channel

Piling
Piling Construction - Plant, Methods & Sequence
Piling
Piling Construction - Plant & Methods
 Pile Load Test
Piling

ⓒ David H Moloney
Sheet Pile Shaft Temporary to Support Excavation
ⓒ David H Moloney

Drive Sheet Piles Excavate & install bracing

Construct Concrete Structure Backfill, remove bracing & sheet piles

General Items
Sheet pile Temporary Shaft

3D Animation to show Sequence

ⓒ David H Moloney
Secant Pile Construction - Sequence, Plant & Methods

For construction details see my YouTube Channel

3D image to show Sequence, Method & Plant.

ⓒ David H Moloney
Diaphragm Wall Construction - Sequence, Plant & Methods

For construction details see my YouTube Channel

3D image to show Sequence, Method & Plant.

ⓒ David H Moloney
Contents
 Jetty for Oil Tankers
Marine

ⓒ David H Moloney
 Quay Wall
Marine

ⓒ David H Moloney
 Breakwater
Marine

ⓒ David H Moloney
 Dredging & Reclamation
Marine

ⓒ David H Moloney
Contents
Reinforced Wall Construction Sequence

3D image to show Sequence, Method & Plant.

ⓒ David H Moloney
 Reinforced Wall Construction Sequence
Concrete

ⓒ David H Moloney
 Reinforced Structure Construction Sequence
Concrete

ⓒ David H Moloney
Reinforced Construction Tank Sequence David H Moloney

ⓒ David H Moloney
 Oil Interceptor Used to capture oil / fuel from leaks or spillages that are washed down
drains every time it rains.
Miscellaneous
 Oil Interceptor
Concrete
Earthworks
Excavation for Underground Pump station

Brief Description

Faces of excavation Stepped &

Well-point Dewatering used.
Contents
Main Equipment

Slug Catcher Flares

Generators – Gas Turbine

Path of Construction 42

Liquid Train Gas Train Compressors

Pipe Rack

The Pipe Racks carries pipes and cables.

The pipes contain gas and liquids that are transported to and from the
different processes.
Piperack Construction Animation

The Pipe Racks carry pipes and cables

between the different processes..
Pipe Rack
Pipe Rack - Expansion Loop

46
Pipe Rack – Scaffold Underslung

Hanging Scaffold

Stairway Tower

Gas Processing Facility

Pipe Rack under construction
Slug Catcher

The slug catcher buffers the incoming gas and liquid, from the wellheads, it
also separates the gas from the liquid.
Slug Catcher Construction Sequence Animation

Separates the Gas from the Oil & Water

Also to dissipate any pressure surges
Slug Catcher
Steel Circular Tanks Construction

Storage of Oil & Water

 Steel Storage Tank
Structural Steel

ⓒ David H Moloney
Steel Circular Storage Tank – Construction ⓒ David H Moloney
Contents
Piping Spool Fabrication

Piping Spools are pre-fabricated from pipes and pipe fittings in fabrication shops to
reduce on site fabrication costs and provide better quality.
Pipe Spools examples
 Spool Fabrication on site
Pipework
Spool Fabrication Steps

NDT
Cut Non Destructive
Testing

Bevel PWHT
Post Weld Heat
Treatment

Fit-up Blasting

Weld Painting
Welding Trials
Welding

Fit up Clamp
 Spool Fabrication - Pipe Rolling & Cutting Table
Pipework
 Spool Fabrication Spool Rolling & Welding
Pipework

W. Soule & Company USA

 Spool Fabrication - Automatic Welding with Pipe Rolling
Pipework

W. Soule & Company USA

 Welding Positioner / Turntable
Pipework

Anyeke.com.my
Contents
Erect Flares / Columns & Vessels
Cranes Heavy Lift Animation

Lift column from the horizontal and

rotate into the vertical
Erect Flares / Columns & Vessels - 3D Simulation

Gas Processing Facility

Flares / Columns / Vessels Erection

Tandem Lift to tilt flare

from horizontal to vertical

Tail
Crane
Trunnions

Main
Lift
Crane

Demag CC180-1 300 t crawler crane

72m boom & 42m luffing jib Path of Construction 70
Contents
Electrical Sub Station 3D Model

3D Model – Used to provide a better understanding

Main Substation Horizontal Cross section

HVAC Room
Heat, Ventilation, & Air Conditioning Chillers
Local
UPS Equipment
Battery Room
Room Room

Transformer Bays
Electrical Sub Station

3D Model - Horizontal cross sections moving upwards

Electrical Sub Station

3D Model - Vertical cross sections moving along building

Structural Steel Building Single Storey
3D images to show Construction Sequence.

Step 1 Set-out Grid Lines Step 2 Holding Down Bolts Step 3 Erect 1st Bay

Step 4 Erect 2nd Bay Step 5 Erect following Bays

ⓒ David H Moloney
 Steel Building Single Storey
Structural Steel

ⓒ David H Moloney
Structural Steel Building Multi Storey
3D images to show Construction Sequence.

Step 1 Set-out Grid Lines Step 2 Holding Down Bolts Step 3 Erect 1st level use core for stability

Step 4 Complete 1st Level Step 5 Erect following Levels Step 6 Plumb & Align Structure

ⓒ David H Moloney
 Roof Covering
Structural Steel

Brief Description

Sequence is
Fix bottom sheet
Fix Vapour barrier
Fix Top Hat section and clips
Fit Insulation
Fix top sheet

ⓒ David H Moloney
 Roof Covering
Structural Steel

ⓒ David H Moloney
 Roof Covering
Structural Steel

ⓒ David H Moloney
 Roof Covering
Structural Steel

ⓒ David H Moloney
Contents
Onshore Gas Pipeline Construction Sequence

Gas Processing Facility

Construction of Azerbaijan Oil Pipeline 42” by 450km.
Overview Construction Sequence

A typical sequence of activities is- surveying and setting out, preparing the land, stringing out the pipes along the
route, excavating the trench, welding and laying the pipes, backfilling the trench with the excavated soil, and
reinstating the land to its original condition.
.

Crossing Railway, Roads, Rivers, etc.

Pump Station
 Oil Pipeline 42”
Contents

Overview
Surveying & Setting Out
Clearing & Grading
Double Jointing i.e. welding 2 pipes together
Stringing out Pipes
Bend Pipes for changes in direction sideways and up & down
Welding Pipes into a string, Test Weld by X Ray.
Anti-corrosion Coat to Joints
Trenching i.e. excavate trench
Lowering pipe string into trench
Backfilling Trench
Reinstatement of Pipeline ROW (Right-of-Way)
Reinstatement of River Banks
Crossing - Horizontal Directional Drilling
Crossing - Thrust Boring
Crossing - River Pause Slides to Read
Hydrotest & Pigging
Tie-in i.e. connect to existing pipeline
Miscellaneous
Overview Pipeline Construction Animation

To see animations, view YouTube film.

Cable laying 132KVa Electric
 Cable Laying
Pipework

Brief Description

132 kVa Cable laying .

 Cable Laying
Pipework
 Cable Laying
Pipework
 Cable Laying
Pipework
Contents
 Horizontal Directional Drilling
Pipework

Brief Description

Horizontal Directional Drilling under a taxiway.

Process
1. A pilot hole id drilled to the designed profile
2. A reamer is pulled back through the hole to enlarge it
3. A pipe string is pulled into the hole.
 Horizontal Directional Drilling
Pipework
 Crossings – River, Motorway & Rail
Pipework
Overview Pipeline Crossings Construction Animation
 Micro Tunnelling
Tunnels
 Micro Tunnelling Sequence David H Moloney
Tunnels

ⓒ David H Moloney
Contents
Road Construction

Includes Sequence, Methods & Equipment

Road Construction Sequence Animation
Asphalt Pavement
Fencing & Gates

Includes Sequence, Methods & Equipment

Fencing
Sequence of Construction
Clear Scrub & Grade ground
Fix Corner & Strainer Posts
Fix Intermediate Posts
Fix Line Wire, Chain-link & Razer wire
Concrete ground beam

ⓒ David H Moloney
Miscellaneous
Fencing
Miscellaneous
Fencing
Miscellaneous
Fencing
Miscellaneous
Fencing
Contents
Setting out & Surveying
Setting out & Surveying
Contents
 Emergency Phone Numbers & Response
Health, Safety & Environment
 Dashboard is a single page, graphical representation of
HSE Monitoring & Reporting - Dashboard current HSE Issues and historical trends
Health, Safety & Environment
Health, Safety & Environment
Safety Precautions
 Safety Training on Site
Miscellaneous
Exposed Existing Underground Utilities

ⓒ David H Moloney
 Existing Underground Utilities & Overhead Cables - Safety Measures
Health, Safety & Environment

ⓒ David H Moloney
Health, Safety & Environment
Trench - Safety Measures
 Trench - Safety Measures
Health, Safety & Environment

ⓒ David H Moloney
 Site Safety Posters examples
Health, Safety & Environment
 Air, Noise, Water & Soil Pollution
Environmentally Friendly Site
Health, Safety & Environment
Health, Safety & Environment
Water Pollution Prevention
 Segregation of Waste
Health, Safety & Environment

Segregation of waste for proper disposal and

recycling. Less waste goes to landfill and
hazardous waste is treated to make it safe.

Colour Code for Skips & Bins

Contents
Staff Directory

Brief Description

List of staff and their

contact details
Daily Work Record

Brief Description

Daily Work Records showing the

allocation of resources, materials and
work activities carried out daily.
Organogram

Brief Description

Shown are the line and

lateral relationships
between the various team
members and their relative
position in the site
organisation.
Filing System
Contents
 Dashboard is a single page, graphical representation of
Quality Assurance Dashboard current statistics and historical trends
 Site Laboratory
General items
Contents
Progress Monitoring & Reporting - Dashboard
Dashboard is a single page, graphical representation of current progress and historical trends

ⓒ David H Moloney
Programme for Construction
Gantt Charts to plan and schedule projects
 Programme using Timeline & 3D Images

POTABLE/FIRE WATER TANK

Pump House

Chiller Plant
Primary Substation-

IRRIGATION WATER TANKS

Irrigation Pump House-

Airport Central Utility Yard

 Pump House

Piling
Chiller Plant-714
Pump House-
715

Primary Substation-711

Irrigation Pump House-

716
Chiller Plant-714
Pump House-
715

Primary Substation-711

Irrigation Pump House-

716

IRRIGATION WATER TANK

Chiller Plant-714
Pump House-
715

Primary Substation-711

Irrigation Pump House-

716

IRRIGATION WATER TANK

Chiller Plant-714
Pump House-
715

Primary Substation-711

Irrigation Pump House-

716

IRRIGATION WATER TANK

 POTABLE/FIRE WATER TANK

Chiller Plant-714
Pump House-
715

Primary Substation-711

Irrigation Pump House-

716

IRRIGATION WATER TANK

Time Chainage Diagram The chart has two axis: one for time and the other for location
A legend explains meaning of the colours, symbols and line types

Sample Only
Histogram Charts for Resources & Outputs

Concrete, Manpower, TBM,

Manpower per Discipline Concrete per Location

Numbers for each month of the Project Quantity for each month of the Project

ⓒ David H Moloney
Plant & Equipment List & Worker’s Job Titles
ⓒ David H Moloney
Contents
Temporary Contractors Site Facilities

Brief Description

Site Offices, Camp Accommodation for

1,250 workers, Canteen, Recreation,
Fabrication shops, Stores, Plant Yard. In five
locations along the route.

ⓒ David H Moloney
General Items Welfare Facilities

Toilets – Washing

Canteen, Drying Room, Toilet & Generator

ⓒ David H Moloney
General Items
Site Hoarding examples

ⓒ David H Moloney
General Items
Temporary Electricity Supply & Tower Lights

ⓒ David H Moloney
General Items
Wheel Wash Drive-through

ⓒ David H Moloney
General Items
Wheel Wash Drive-through
General Items
Weighbridge & Sheeting Access

ⓒ David H Moloney
General Items
Dust Suppression

ⓒ David H Moloney
General Items
Dewatering

Brief Description

Construction dewatering is the removal or

drainage of groundwater and or surface /
rain water usually by pumping to keep the
works dry.

ⓒ David H Moloney
General Items
Dewatering

ⓒ David H Moloney
Quarry & Aggregate Production

3D image to show Sequence, Method & Plant.

ⓒ David H Moloney
General Items
Quarry & Aggregate Production
Concrete Batching Plant David H Moloney

ⓒ David H Moloney

Concrete batching plant comprises - concrete mixer, control cabin, silos for cement and fly ash, aggregate bins
and conveyor belt system to feed the mixer. Also aggregate storage bays and water storage tanks.
The mixing is computer controlled and has a dynamic screen display, showing the process. Material storage
capacity to match two days concrete production
 Concrete Batching Plant
Concrete

ⓒ David H Moloney
General Items
Concrete Batching Yard 3 Nr Mixers
Reinforcement Cutting & Bending Yard David H Moloney

Reinforcement in 12 m lengths. Delivery in 3 ton Bundles Reinforcement cut to length by Shearing Machine

Reinforcement Bent to Shape by Bending Machine Reinforcement that is cut and bent is Bundled for delivery to work site
ⓒ David H Moloney
 Reinforcement Cutting & Bending
Concrete

ⓒ David H Moloney
Contents
Notes
Production by David H Moloney

My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

ⓒ David H Moloney