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Oil & Gas Engineering Training

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Dear colleague,
I am glad to share with your this educative material on the
Engineering of Oil & Gas facilities.
I developed it for classroom training sessions which I have been
conducting since 2009.
This material will give you an overview of the work and deliverables of
the different engineering disciplines.
I also thrived to produce workflow visuals to help understand the
work sequence of each discipline and how they interface.
I wish you an enjoyable journey within Engineering

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Oil & Gas Engineering Training


HSE Moment
Intro, scope & objectives
Project Engineering
The Design Basis
Discipline presentations
Field engineering
Schedule
Quality

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Do you think that HSE is only for HSE professionals?

Do you think you cannot do your bit when visiting a Site?

Any thing wrong your are able to identify on the following


pictures?

Lets see

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Do you think that HSE is only for HSE professionals?

Comments?

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Comments?

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Comments?

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Comments?

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Comments?

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Comments?

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Site visits?

You, me

We can all do our bit to point out UNSAFE situations

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Oil & Gas Engineering Training


HSE Moment
Intro, scope & objectives
Project Engineering
The Design Basis
Discipline presentations
Field engineering
Schedule
Quality

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Training Objectives
To give a detailed knowledge of what
engineering of oil and gas facilities consist of
To describe the activities and show a sample
deliverable in the various disciplines
To explain the challenges

Scope

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Oil & Gas Engineering Training


HSE Moment
Intro, scope & objectives
Project Engineering
The Design Basis
Discipline presentations
Field engineering
Schedule
Quality

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Design
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Installation

Procurement

Manufacturing

Construction
& erection

Inspection &
tests

Shipping

Hand-over

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Home office (Paris)
Project management
Detail Engineering (part)
Procurement

Engineering SubContractor (Delhi)


Detail Engineering (part)

Shipyard (Korea)
Hull Engineering &
Fabrication

Satellite office (Pau)


Detail Engineering (part)

Fabrication yard
(Nigeria):
Fabrication (part)

Offshore (Nigeria):
Installation, commissioning,
start-up

Shipyards (Singapore &


Malaysia)
Topsides Fabrication &
Integration

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Project

Engineering

Procurement

Construction

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Project

Instrumentation
& Control

Layout
& Piping

Process

Engineering

Procurement

Construction

Electrical

Equipment

Civil

Safety

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Engineering document register


Document
revision

Discipline code
A

Instrumentation & Control

Civil engineering

Electrical

Project general documents

Mechanical

Safety

Piping & Layout

Processes

Steel Structures

Vessels Heat exchangers

Materials Welding

Document
number

Document title

48104

Service building instrument. rooms cables routing

48102

Trouble shooting diagrams

48134

F&G system architecture drawing

50100

Instrument index

50003

Spec for instrument installation works and service

50960

Instrument Data sheets for temperature switches

50110

Requisition for pressure relief valves

62059

General plot plan

62020

Piping details standard

Installation drawings

62070

Piping general arrangement Area 1

Detail drawings

60100

Special items list

Diagrams

62250

Piping isometrics booklet

Lists Bill of Quantities

60000

Pipes and fittings thickness calculation

Isometrics

62351

Calculation note CN1 - piping stress analysis

Calculation notes

60001

General piping specification

Specifications

60103

Data sheets for station piping material

Data sheets

60200

Requisition for pipes

Requisitions

Document code

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Diagram

Key plan

Drawing

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Drawings common
sizes & scales

A0 = 840x1188

A1 = 594x840
A2 = 420x594
A4 =
210x
297

A3 =
297x
420

Scale

1m =

1/1000

1 mm

1/500

2 mm

1/250

4 mm

1/100

1 cm

1/50

2 cm

1/33

3 cm

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Engineering schedule

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Engineering
resources

Commissioning
9%

Electrical
9%

Mechanical
Equipment
6%

Instrumentation
/ICSS/Telecom
10%

Naval
4%
Process
2%
Others
6%

Structural
23%

~1,000,000 man-hours
Piping
31%

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Client
Documents
submitted
to client

Approval/
Comments

Design basis:

Documents for Construction:

- Functional
requirements

Construction drawings &


specifications

Engineering

- Client
specifications

Documents for Purchase:


bill of quantity & specification

- Design codes
Documents
submission

Comments

Vendors

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Oil & Gas Engineering Training


HSE Moment
Intro, scope & objectives
Project Engineering
The Design Basis
Discipline presentations
Field engineering
Schedule
Quality

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Design Basis
Infrastructure:

Feedstock and products flow


Feedstock composition
Battery limit conditions
Equipment Spare

Pressure (bar)

Process facilities:
50

Administrative and technical


buildings

45
40

Control room

35

Access road

30

Site fencing, gates, check point

25
20

Performance:

15

Products specifications

10

Energy efficiency, emissions

Design criteria:
% of over design

5
0
-85

Utilities:
Electric power supply
Other utilities

-80

-75

-70

-65

-60

-55

Environment data:
Min/max temperature
Rain/snow fall
Wind
Geological conditions

Systems:
Process control
Fire/gas alarm
Public address, LAN, PABX

Applicable codes and standards:


International standards
Local rules

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Oil & Gas Engineering Training


HSE Moment
Intro, scope & objectives
Project Engineering
The Design Basis
Discipline presentations
Field engineering
Schedule
Quality

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Engineering disciplines
Process
Equipment
HSE
Civil
Layout
Piping
Instrumentation
Electrical

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Functional requirements example of a gas compression station


Gas composition

Performance

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TEG

HP Compression & TEG


Gas Injection

1200 psig
3000 psig

500 psig

200 psig

IP Compression
From Wells
165 - 205 F

HP Separator
500 psig

5500 psig

50 psig

LP Compression

5 psig

Cooler

Emul. Treater
50 psig 150 F

Process Scheme
Optimization

Degasser
5 psig

Oil Production

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Process simulations

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Process Flow Diagram (PFD)

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Equipment list

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Thermodynamic
calculations

Heat & Material


balance

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Equipment
sizing

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Process data sheet

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Fluid list

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Piping & Instrumentation Diagram (P&ID)

Line List

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Piping & Instrumentation Diagram (P&ID)

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P&IDs legend & symbols

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Line sizing

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Process automations: Cause & effect chart

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Process control

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Process safety

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ESD logic diagram

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ESD simplified diagram

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Flare Report

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Operating manual

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Quiz: Is this a P&ID?


a PFD?

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Engineering
Process
Equipment
HSE
Civil
Layout
Piping
Instrumentation
Electrical

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Process design
PFDs
H&M balance

Process
data
sheet

Equipment
specification
Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.

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Equipment list

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Rotating machinery

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Pressure vessels

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Heat exchangers

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Packages

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Process data
sheet
Mechanical
data sheet

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Vessel guide drawing

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Material Requisition

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Bid technical evaluation

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Vendor design

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Equipment summary

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Engineering
Process
Equipment
HSE
Civil
Layout
Piping
Instrumentation
Electrical

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HAZOP Review
RISK LEVEL
RISK MATRIX

FREQENCY

SEVERITY

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HAZOP Action sheet

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Fire Fighting

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Fire Water demand


calculation note

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Fire Water P&IDs

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Deluge system
arrangement drawings

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Fire fighting equipment location drawing

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Passive fire protection drawing

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Passive fire protection

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Fire & Gas detection layout

Hazardous
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classification
drawing

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Quantitative Risk
Analysis (QRA)

Case stuy: Gas leak from random piping


component rupture
Cause: installation error, corrosion, material
defect
Possible consequence: Dispersion without ignition
/ jet fire / flash fire / explosion
Section considered: Compressor building

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Quantitative Risk
Analysis (QRA)

Step 1:
Identification and characterisation
of initiating events

risk components
*failure rate
(from statistics)

Gas leak inside compressor buidling due to


component rupture

Frequency (event/year)
Outflow rate (kg/s)

Hole size
(% of component section)
5%

20%

Full

1,11E-01

5,06E-04

6,83E-05

5,7

90,8

2270,0

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Quantitative Risk Analysis (QRA)


Step 2: Event tree analysis
Release Frequency

Probability of immediate
ignition for 1-50 kg/s release
rate is 7% (from statistical data)

Immediate ESD & Fire


Fighting
ignition

0,998
0,070

Delayed
Ignition

Explosion/
Flash-fire

Consequence Event

Frequency (ev/y)

Gas detectors are provided inside the building, that


activate isolation and depressurization.
It is
Jet fire ESD & FF
7,779E-03
assumed that they operate 95% of the time.

0,002

Jet fire no ESD & FF

1,520E-05

Probability of explosion vs flash fire depends


on mass of gas and degree of confinement

1,11E-01
Release/yr
0,949

Dispersion

9,827E-02

0,120

Explosion

1,774E-05

0,880

Flash fire

1,301E-04

Dispersion

5,133E-03

0,930
0,028
0,051
0,972
Yes

Frequency (event/year)
Jet fire ESD & FF
7,779E-03
Jet fire no ESD & FF
1,520E-05
Explosion
1,774E-05
1,301E-04
Flash Fire
Dispersion
1,034E-01

No
B04a/b/c/d

5%

Probability of delayed ignition takes into


account equipment explosion protection (Ex)

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Quantitative Risk Analysis (QRA)

Step 3:
Consequence evalutation

Overpresssure (bar)

0.2

0.1

0.01

Distance (m)

96

167

1270

CONSEQUENCE CLASS

QUANTITATIVE CRITERIA

EFFECTS

MINOR

0.1 bar locally (within 10m)

No effect, no damage

SIGNIFICANT

0.1 bar locally (within 50m)

Limited damage to plant and operators

SEVERE

> 0.1 bar within plant

Damage to plant and operators

MAJOR

> 0.1 bar on populated areas

Damage to plant, operators & public

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Quantitative Risk Analysis (QRA)

Unacceptable
risk
area
Design change necessary

Final step: classification of risk


Release Frequency

Immediate ESD & Fire


Fighting
ignition

Delayed
Ignition

Explosion/
Flash-fire

Consequence Event

As Low As
Reasonably
Practicable

Plant
Management measures
Acceptable risk area

Frequency (ev/y)

0,998

Jet fire ESD & FF

7,779E-03

0,002

Jet fire no ESD & FF

1,520E-05

0,070

1.0E-02

1,11E-01
Release/yr
0,949

Dispersion

9,827E-02

0,120

Explosion

1,774E-05

0,880

Flash fire

1,301E-04

Dispersion

5,133E-03

0,930
0,028
0,051
0,972
Yes

Frequency (event/year)
Jet fire ESD & FF
7,779E-03
Jet fire no ESD & FF
1,520E-05
Explosion
1,774E-05
Flash Fire
1,301E-04
Dispersion
1,034E-01

No
B04a/b/c/d

5%

1.0E-03

1.0E-04
Unlikely
1.0E-05
Rare
1.0E-06

Minor

Significant

CONSEQUENCE CLASS

QUANTITATIVE CRITERIA

EFFECTS

MINOR

0.1 bar locally (within 10m)

No effect, no damage

SIGNIFICANT

0.1 bar locally (within 50m)

Limited damage to plant and operators

SEVERE

> 0.1 bar within plant

Damage to plant and operators

MAJOR

> 0.1 bar on populated areas

Damage to plant, operators & public

Severe

Major

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Environmental Impact Assessment (Air quality dispersion


analysis)

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Noise Map

dB(A)

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Engineering
Process
Equipment
HSE
Civil
Layout
Piping
Instrumentation
Electrical

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Process design
PFDs

P&IDs

H&M balance

Piping
Instrumentation

Process
data
sheet

Equipment
specification
Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.

Vendor
drawings

Layout
Civil
Electrical

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Grading plan

Required finish level

Native soil elevation

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Vendor information

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Foundation
Calculation

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Foundation
drawing/
re-inforcement

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Foundation
drawing/
Formwork

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Civil works
specification

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Loading data

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Structural design

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Calculation note

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Structural
drawings

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Architectural drawings

Equipment layout
drawing

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Heating, Ventilation &Air


Conditioning (HVAC)

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Civil Works Installation Drawings

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Standard drawings

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Engineering
Process
Equipment
HSE
Civil
Layout
Piping
Instrumentation
Electrical

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Process design
PFDs

P&IDs

H&M balance

Piping
Instrumentation

Process
data
sheet

Equipment
specification
Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.

Vendor
drawings

Layout
Civil
Electrical

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Layout/
principles

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Layout/vendor drawings

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Layout/consideration for all networks

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General Plot Plan

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Unit Plot Plan

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3D modelling

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3D model clash check

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3D model review

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Equipment handling

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Engineering
Process
Equipment
HSE
Civil
Layout
Piping
Instrumentation
Electrical

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Process design
PFDs

P&IDs

H&M balance

Piping
Instrumentation

Process
data
sheet

Equipment
specification
Rotating
Pressure vessels
Fired equipment
Heat exchangers
Packages etc.

Vendor
drawings

Layout
Civil
Electrical

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Line Diagram

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Piping Layout drawing

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Isometric drawing

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Piping Pre-fabrication

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Post Weld Heat


Treatment

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Piping Inspection and testing

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Piping General
Arrangement drawing

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Calculations

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Standard Pipe Support


drawings

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Plot
Plan

Piping
line
diagram

Piping installation work process

Piping
studies
& layout

Piping 3D
modelling

Piping stress analysis

Piping
isometric
drawing

Stress
OK?

Process
OK?

Piping
isometric
drawing
IFC

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Material Selection

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Material Selection Diagram

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Process Fluids list

Piping material classes

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Piping material
classes

Piping material class specification

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Piping material classes specification

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Piping material classes specification

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Piping material classes specification

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Piping material requisition

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Engineering
Process
Equipment
HSE
Civil
Layout
Piping
Instrumentation
Electrical

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Piping &
Instrumentation
Diagram (P&ID)

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Instrument list

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Level sketch

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Instrument data sheet

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Process Control System

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System
Architecture
drawing

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Process
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Control narrative

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Mechanical Equipment Control

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Emergency shutdown

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The instrument hardware


Instrument room
Marshalling

Controller

cabinet

cabinet

Control room

VDU

PT

JB

Process
line

CPU

LAN
Secondary cable
Multi cable

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Junction Box
drawing

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Instrument location
drawing

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Building detail drawing/


Telecom and PAGA layout

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Instrument standard
installation drawings

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Junction box wiring

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Cable routing drawings

Cable list

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Instrument bulk Material Take-Off

ITEM

QUANTITY

DESIGNATION

195

Gauge adapter x

37

Block manifold 2 valves (Gas)

23

Block manifold 5 valves (Gas)

Ball valve 12mm

300m

200

Reducer 12mm x

50

Union tee 12 x 12 x 12mm

50

Female connector 12mm x

350

Male connector 12mm x

10

Plug NPTF

11

Plug NPTM

Tubing 12mm OD x 1mm

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Cable routing inside


technical room

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Instrumentation &
control rooms layout

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Screen displays

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Instrument loop diagram

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Engineering
Process
Equipment
HSE
Civil
Layout
Piping
Instrumentation
Electrical

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Electrical consumer list

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Electrical Load
Summary

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General One
Line
Diagram

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Generators

Switchgear

Transformer

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Equipment data sheet

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Switchboard
Single Line
Diagram

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Switchgear Typical Diagram

Bus Voltage (Volts)

VOLTAGE OF MS-001 (STUDY1)

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9900
9800
9700
9600
9500
9400
9300
9200
9100
9000
8900
8800
0.0

2.5

5.0

7.5

10.0
12.5
Time (Seconds)

15.0

17.5

20.0

FREQUENCY OF MS-001 (STUDY1)


Bus Frequency (Hz)

50.0

49.5

49.0

48.5

Calculations

48.0

47.5

47.0
0.0

2.5

5.0

7.5

10.0
Time (Seconds)

12.5

15.0

17.5

20.0

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routing drawing

Cable schedule

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Typical
installation
drawings

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Block Diagram

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Trouble shooting
diagrams

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Lighting layout

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Lighting illumination level

Iso lux
curves

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Electrical equipment layout

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Electrical Control
System

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Electrical
Control System

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From main
power
generators

From emergency
(diesel)
generators

Electrical load shedding

To normal consummers
e.g. pumps in process
and utility units

To essential
consummers e.g. fire
water pump

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Oil & Gas Engineering Training


HSE Moment
Intro, scope & objectives
Project Engineering
The Design Basis
Discipline presentations
Field engineering
Schedule
Quality

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Field Engineering

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Site Query

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Site MASTER set of documents

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Oil & Gas Engineering Training


HSE Moment
Intro, scope & objectives
Project Engineering
The Design Basis
Discipline presentations
Field engineering
Schedule
Quality

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MONTH
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
PROJECT SCHEDULE
PLANT START-UP
PIPING PRE-FABRICATION & INSTALLATION
X X X X X X X X X X
PIPING MATERIAL & DRAWINGS AT SITE
PIPING MATERIAL MANUFACTURING & SHIPPING
X X X X X X
PURCHASE OF PIPING MATERIAL
TECHNICAL & COMMERCIAL CLARIFICATIONS
X X
CALL FOR TENDER FOR PIPING MATERIAL
PREPARE PIPING MATERIAL TAKE-OFF
X
PIPING ROUTING STUDIES
X X X
PIPING & INSTRUMENTATION DIAGRAMS (PIDs)

2 3

4
2

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simulations
Process
data sheet
Equipment
selection
&
purchase
Vendor data

Foundation
drawings

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Engineering schedule

Safety valves
duty & data
sheet (Process)

Size
& weight
estimates

Safety valves
inquiry and
purchase
(procurement)

Safety valves
location & piping
routing
(piping/layout)

Estimates must be done


to meet the schedule

Piping calcs &


supports
(piping/stress)
Steel structure
design and
drawings (civil)

Supports
& loads estimates
Purchase steel
(manufacturer)

Safety valves
sizing & drawings
(vendor)

Fabrication
(manufacturer)
Shipping

Structure
at Site

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What the
Vendor
supplied

What
Engineering
designed

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Oil & Gas Engineering Training


HSE Moment
Intro, scope & objectives
Project Engineering
The Design Basis
Discipline presentations
Field engineering
Schedule
Quality

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Engineering Quality Assurance:


Engineering document register

Document
number

Document title

Document
revision

48104

Service building instrument. rooms cables routing

48102

Trouble shooting diagrams

48134

F&G system architecture drawing

50100

Instrument index

50003

Spec for instrument installation works and service

50960

Instrument Data sheets for temperature switches

50110

Requisition for pressure relief valves

62059

General plot plan

62020

Piping details standard

62070

Piping general arrangement Area 1

60100

Special items list

HERVE
BARON

Engineering Quality Assurance:


Document checking and distribution

HERVE
BARON

Engineering Quality Assurance:


Document revision

HERVE
BARON

Engineering Integrity: Site Query from Construction

HERVE
BARON

Interface
Agreement

Section/Step 1

Section/Step 2

HERVE
BARON

Interface definition

HERVE
BARON

I hope you enjoyed these few slides. They date from the first session of my
Engineering training, back in 2009.
The training has since then grown a lot. It today contains 3 to 4 times as much
information.
Have a look at the on-line PREVIEW of the current training:
https://www.dropbox.com/s/6ea0gaxcj7xjqz2/Eng%20Mgt%20Training%202014.pdf

Welcome to one of my LIVE training sessions to gain much much more!


Venues and dates are on my blog:
http://www.toblog.fr/en/baron.html