Titolo presentazione

Project and programme management B

sottotitolo
EPC Phases
 Milano, XX mese 20XX
Prof Mauro Mancini

© Mauro Mancini

AGENDA

• Plant’s Project Phases

• Engineering phase
• Procurement Phase
• Construction/assembly/executionPhase
• Commissioning Phase

© Mauro Mancini

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Plant’s Projects Phases

PLANNING/CONTROL
engineering
OPERATING
PHASES
procurement

construction/assembly

start-up/testing

© Mauro Mancini

Plant’s Projects Phases

PHASE RATIONALE
Systems (functional units of
Base Engineering
the plant)
Detailed Engineering Specialist disciplines

Procurement Product classes

Work’s processes/physical
Construction/Assembly
areas
Start-up/testing Systems

© Mauro Mancini

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Plant’s Projects Phases
CONSTRUCTIVE
Base FUNCIONAL Detailed DESIGN
Engineering SPECIFICATIONS Engineering

SUPPLIER
PURCHASE DATA
SPECIFICATIONS

FUNCTIONAL Procurement
PERFORMANCE
TESTING
CONSTRUCTIVE
MODIFICATIONS MATERIALS

Construction
/Assembly
Start-up/ SYSTEMS
Testing

© Mauro Mancini

Engineering Phase

• Designing the engineering of a plant means to

define coherently, with an increasing level of
detail, technical specifications of all plant sub-
systems (primary and auxiliary) and the relative
integration ways.

• Base Engineering
• SYSTEMIC APPROACH

• Detailed Engineering
• ENGINEERING DISCIPLINE APPROACH

© Mauro Mancini

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 Engineering Phase

Base Engineering
• From requirements (functional, performance,
technological, constructive) given by the
customer, until the complete definition of the
plant (articulated in primary and auxiliary
systems)
PRIMARY SYSTEM

SECONDARY
SECONDARY
SYSTEM:
SYSTEM:
Instrumentation
Electric Power
and control
© Mauro Mancini

Engineering Phase

Base Engineering
• project requirements’ analysis
• technological process choice
• plant collocation
• plant configuration and its articulation in sub-systems
• automation level definition
• sub-systems characteristics definition
• layout definition
• health, security and environmental impact matters
analysis
• operating management politics definition
• design criteria and constraints for detailed engineering
definition

© Mauro Mancini

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 Engineering Phase

Block Diagram Overall Layout Equipment List

Process Flow
Detailed Layout Data Sheet
Diagram

Material Balance
Buried Network
Energetic Balance
COMPONENTS
Process &
Aerial Network
Instrument Diagram

PID mechanized

LAYOUT

PROCESS
© Mauro Mancini

Engineering Phase

Detailed Engineering
• Multidisciplinary activity through which technical
specification of plant components and relative
ways of installations are defined, on the basis of
prefixed criteria, standards, rules, to supply
necessary materials (material take-off) and to
define ways of construction/assembly (sketches)

© Mauro Mancini

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 Engineering Phase
AT1

Base Engineering

Detailed
Engineering
Front End
Engineering
Engineering for Requisitioning
and Procurement
Engineering for
Construction/Assembly
Engineering during
Construction

© Mauro Mancini

Engineering Phase

• Detailed Engineering
• Front End Engineering task is to define design choice
fundamental for each specialist discipline, coherently
with base engineering, to start supply campaign
through items’ data sheet

© Mauro Mancini

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Diapositiva 11

AT1 per completezza non bisogna aggiungere anche "base engineering all'inizio"?
Agnese Travaglini; 05/03/2016
 Engineering Phase

• Detailed Engineering
• Engineering for Requisitioning and Procurement
develops through the following:
• formulation of technical specifications for Request for
Bid/Order;
• formulation of technical opinions on offers coming from
suppliers;
• control and approval of technical documentation
coming from selected supplier

© Mauro Mancini

Engineering Phase

• Technical documents
• to specify technical characteristics of a
plant/component
• to specify ways of construction, assembly, testing,
exercise, maintenance
• to show the rightness of the project for rules absolving,
authorizations, etc.

© Mauro Mancini

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 Engineering Phase

• Technical documents Life-Cycle

• planning
• elaboration
• filing
• transmission (if the document is used during the project
in progress)
• research and rendering (if the document is used in
other projects)

© Mauro Mancini

Engineering Phase

© Mauro Mancini

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 Procurement Phase

• Site Logistics
• Product Support Logistics
• Materials Logistics

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Procurement Phase

• Materials logistics can be divided in:

• Procurement  order for supplier
• Materials Management  to guarantee the
presence of materials on site

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 Procurement Phase

• Procurement

• Supplied materials:
• construction materials;
• plant components;
• consumption materials;
• operating means and advices.

© Mauro Mancini

Procurement Phase

• Procurement

• Vendor List
• Subcontractor List

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 Procurement Phase

• Procurement Phases
• Emission of “Purchase Specification” (from Engineering
and Procurement);
• Emission of “Inquiry for Bid” (from Procurement and
supplier inserted in vendor list);
• Technical tabulation of received proposals (from
Engineering);
• Economic tabulation of received proposals (from
Procurement);
• Emission of “Inquiry for Purchase” (from Engineering);
• Order emission (from Procurement);
• Final approval of supplier technical documentation
(from Engineering).

© Mauro Mancini

Procurement Phase

• Materials Management

• Expediting
• Inspecting and testing
• Transports
• Reception/storing/handling of materials in site

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 Procurement Phase

• Expediting
• This phase guarantees the control of milestones
corresponding to the right progress of the project

• Aims to obtain from the supplier information about:

• furniture progress
• technical documentation development
• completion of foreseen testing

© Mauro Mancini

Procurement Phase

• Expediting Activities
• reunions among order manager, supplier and corporate
functions interested
• detailed exam of the order, identifying uncertainty areas
that could determine delivery delay
• control milestones definition and interventions
frequency between them
• actions of reminder (visits, phone calls, meetings)
• expediting report, sent to corporate functions

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 Procurement Phase

• Expediting Activities
• Materials Statur Report
• material description
• number of purchase specification
• number and data of Inquiry of Purchase
• supplier
• number of order
• planned, foreseen and actual date of completion
• planned, foreseen and actual date of testing
• way of testing

© Mauro Mancini

Procurement Phase

• Expediting Activities
• Materials Statur Report
• planned, foreseen and actual date of free factory
rendering
• way of shipment and carrier
• planned, foreseen and actual date of shipment
• planned, foreseen and actual date of delivery to the site
• corresponding activity of construction/assembly
• planned and foreseen date of activities execution
• date for which materials availability on site is required

© Mauro Mancini

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 Procurement Phase

• Transports
• Transport Plan
• ways of transport
• paths
• contract typology (for example “door to door”)
• carrier
• charges
• packaging
• delivery dates

© Mauro Mancini

Procurement Phase

• Transports
• Delivery documents are very important from a
contractual point of view because they activate
payment share from the customer

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 Procurement Phase

• Inspecting and Testing Activities

• participation to technical qualification of suppliers
• verification of suppliers’ quality warranty system and
quality control
• technical supervision through inspections aimed to
verify conformance of materials, processes,
construction methodologies, and order specifications.

© Mauro Mancini

Procurement Phase

• Inspecting and Testing Activities

• The level of supervision depends on supplied
components characteristics and on quality level of
the plant that have to be realized

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 Procurement Phase

• Inspecting and Testing Activities

• 1) PRODUCT CATEGORIES
• 1 – realized on demand on supplier’s engineering
• 2 – realized on demand on E&C society’s engineering
• 3 – purchased from catalogue

• 2) QUALITY CATEGORIES OF PLANTS/SYSTEMS

• 1 – particularly high
• 2 – high
• 3 – normal

© Mauro Mancini

Procurement Phase

• Inspecting and Testing Activities

• Supervision Levels:
• inspection during furniture and presence during testing
(intermediate and final) at suppliers’
• only presence during testing (intermediate and final) at
suppliers’
• acceptance of materials on the basis of documents
(without presence during testing)

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 Construction/Assembly Phase

• Collocated at the end of detailed engineering (that

provides technical documents) and procurement
(that guarantees availability of materials to install),
and precedes start-up and testing phases, where
technical performance of the plant are verified

© Mauro Mancini

Construction/Assembly Phase

• Aspects to consider :
• changes in scope of work
• materials amount revision
• site logistics and transport and communication
infrastructure
• activities programming and temporal profile of
resources’ utilization
• availability of technical documents and materials
on site
• contractual constraints
• plan of security on site
© Mauro Mancini
• problems from operating in strangers countries

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 Construction/Assembly Phase

• Specialist work processes  constructive

sequence
• Constructive area/draft/cube
• Crossing assembly processes and constructive
areas a work package of construction/assembly
phase is obtained
• Subcontracts

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Construction/Assembly Phase

Constructive area approach

Functionally complete system approach

• Materials may be installed:

• per area and per system (e.g. piping)
• per area (e.g. conduits)
• per system (e.g. cables)

© Mauro Mancini

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 Q&A on Engineering & Contracting
phases

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