EPC Project Interdependency

and
Work Flow
Our Belief

Now Everyone Can Be Trained

 Table Of Contents

Topic Page

Introduction to EPC Project Management 5

EPC Project Management work flow 13

Engineering Document Issuance Purpose 19

Engineering Work Flow 21

Procurement work flow 43

On Shore Project Schedule and Schedule dependency 46

Work Front Concept 48

Advance Work Packaging 52

Sample WBS 65

Piping Engineering as case study 73

Vessel Fabrication Work flow as case study 83

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Don’t be like this…

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EPC Project Management
- Introduction

6
 EPC Project Management

EPC stands for Engineering, Procurement, Construction and In some cases, the contractor carries the project risk for
is a prominent form of contracting agreement in the schedule as well as budget in return for a fixed price,
construction industry. called lump sum LSTK depending on the agreed scope of
work.
The engineering and construction contractor will carry out
the detailed engineering design of the project, procure all EPCM stands for Engineering, Procurement, Construction
the equipment and materials necessary, and then construct Management. This type of contract is different to an EPC
to deliver a functioning facility or asset to their clients. Contract in that the Contractor is not directly involved in
Companies that deliver EPC Projects are commonly referred the construction but is responsible for administering the
to as EPC Contractors. Construction Contracts.

The EPC phase of the project is also known as the Execution EPCI stands for Engineering Procurement Construction
phase which normally follows what is know as a FEED or and Installation which is a common form of contracting
Front End Engineering Design phase. The FEED is a basic arrangement in the Offshore Construction Industry. As
engineering design used as the basis for the EPC phase. opposed to an EPC contract, the offshore facility or vessel
that is constructed has to be transported and installed at
The FEED can be divided into separate packages covering the project location.
different portions of the project. The FEED packages are
used as the basis for bidding on when the client offers the EPIC stands for Engineering Procurement Installation
EPC work to the market. Commissioning is typically a Lump Sum Turn Key (LSTK)
type Contract integrating the responsibility going from the
Under an EPC contract, the contractor designs the conception to the final acceptance of one or more
installation, procures the necessary materials and builds the elements of a production system. It can be awarded for
project, either directly or by of the work. all, or part, of a field development.

7
EPC Project Organization

8
EPC Project Organization

9
 Manufacturing/
Design Procurement Shipment
Fabrication

Construction &
Installation Inspection & FAT Hand-Over
Erection

10
Engineering in the Project

11
Engineering Discipline

12
EPC Project Management
- Work Flow

13
 Engineering Work Flow

Engineering work flow concept is required to be fully understand There are many interdependencies between engineering
for someone who involved in the EPC Planning and Activity documents.
Sequencing.
For instance piping routing drawings are issued after the process
This concept is applied when the EPC level 4 schedule is diagram Is defined.
developed.
Most of the documents will usually issued several times, at
The process of engineering work to produce the required different stages to for review as well as to incorporate the
deliverables depends on not only within the functional comments.
discipline itself but also among the process, mechanical and
piping engineering functions. Typically a document is first issued for Internal Review (IFR) of the
other disciplines, then to client for comment (IFC), it will be
Engineering in EPC project is the task of translating a set of returned to be incorporated with the client comments and issue
functional requirement into a full set of drawings and for Approval (IFA), then for construction (IFC) and last once
specifications depicting every detail of a facility, everything is confirmed and will Approve for Construction (AFC)

Engineering involves varieties of specialties, which include :

• Process
•Civil and Structure
•Mechanical
•Piping
•Electrical
•Instrumentation
•General Engineering
•Safety

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The entire strategy is dependent on Engineering and
Procurement providing their deliverables to meet
Path of Construction.

Contractor mobilizes based on Engineering forecast

of IFC EWPs (Engineering Work Packages).

15
 Engineering Work Flow

Engineering phase is very much concerned with documentation.

Engineering Disciplines

Civil and
Activity Process Mechanical Piping Electrical Instrumentation
Structure

Diagrams

Geographical
Drawing

Architecture
Drawing

Calculations

Equipment or
material spec,
data sheet &
requisition

Site work spec

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From Sequential To Concurrent Execution

Engineering Procurement Construction

Engineering

Procurement

Construction
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 Project Execution

The Past: sequential execution

The Present: concurrent execution

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 EPC Project Management
- Engineering Document Issue Purposes

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 Issuing Purpose

FYI For Your Information

IAB Issued For As-Built
ICR Issued For Construction Record
IFA Issued For Approval
IFB Issued For Bid
IFC Issued For Construction
IFD Issued For Design
IFE Issued For Estimate
IFH Issued For Hazop
IFP Issued For Purchase
IFR Issued For Review
IFS Issued For Squad Check
IFU Issued For Use
IFV Issued For Void
RLM Red Line Mark-up
RTS Return To Supplier
SFR Supplier Issued For Review
SFS Supplier Issued For Squad Check
AFC Approved for Construction
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EPC Project Management
- Engineering Work Flow

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 Engineering Workflow

Source : Herve Baron Oil & Gas Engineering Guide 22

slideshare
 Engineering Workflow

Source : Herve Baron Oil & Gas Engineering Guide 23

slideshare
Engineering Document Review Cycle

Rule of credit
Step Review cycle
Increment % Cumulative %

1 Study and design preparation 5% 5%

2 Issue for review (IFR) 10% 15%

3 Issue for approval (IFA) 20% 35%

4 Issue for construction (IFC) 30% 65%

5 Approved for construction 35% 100%

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Engineering Document Review Cycle

P&ID
HAZOP
REVIEW

IFR IFA IFC

PIPING MTO
& PO

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 Document Control

Client

Documents
•Engineering submission cut-off Approval/ •Client Review cycle. (IFR,IFA,IFC,AFC)
submitted
•Maintain internal and external baseline Comments •Client Review duration
to client

Engineering

•Vendor information criticality for client Documents •Vendor duration to incorporate the
submission Comments comments
doc approval
•Vendor delivery estimation

Vendor

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 Vendor Data

Engineering is the integrator of the Plant equipment, and is highly dependent on vendor data

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 Engineering Work Flow – Process Design

Process Design

PFDs
P&IDs
H&M balance

Piping

Instrumentation

Process data sheet

Equipment specification

Vendor drawings

Rotating

Pressure vessels Layout

Heat exchangers Civil

Fired equipment Electrical

Packages etc.
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 Piping Engineering Flow

PFD

Stress
ok ?
Process
equipment
list

Piping
isometric
drawing IFC

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1st Model
review

3D Model 3D
Modeling
2nd model (General)
review

3rd model
review

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 Plot plan
1st Model
review (30%)
Piping Materials

P&IDs 1st issue

2nd model
review (60%)

IFA Instrument cable IFA pipe GA dwg IFA Skid Tie-in report
routing layout
3D Model IFA instrument cable IFA General
IFD P&IDs IFA piping plan dwg
trench &tray layout
IFA Instrument
structural deflection
& stress analysis 3D
E&I main cable IFA structural GA report
routing
location
IFC Instrument IFA tubing routing IFA Structural GA
Modeling
First equipment
vendor dwg
location dwg layout dwg
(Skid
IFA pipe support dwg
Project)
IFI pipe ISO

3rd model
review (90%)

IFC pipe GA dwg

IFC piping ISO

Final piping MTO

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 Skid 3D Modelling – Interdependency

30% PDMS

30% model review

Update PDMS model 30%

Issue close out report 60% PDMS

Report review by EPCC
60% model review
contractor
Update PDMS model 60% 90% PDMS

Issue close out report 90% model review

Update PDMS model 90%

Successor for 60% PDMS (issue close out report)
Issue close out 90% report
IFI for piping ISO
Report review by EPC
IFI [Piping Isometric] contractor
Receive final comment from
IFA cable routing layout
EPC contractor
IFA instrumentation location
IFA pipe support drawing Successor for 90% PDMS (issue close out report)

IFA piping GA drawing EPC contractor review piping GA

IFA piping plan drawing EPC contractor review piping plan

IFA structural GA drawing EPC contractor review pipe support

EPC contractor review structural GA

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Skid 3D Modelling – Piping GA as example

30% PDMS

30% model review

Update PDMS model 30%

Issue close out report 60% PDMS

Report review by EPCC
60% model review
contractor
Update PDMS model 60% 90% PDMS

Issue close out report 90% model review

Update PDMS model 90%

Issue close out 90% report

Report review by EPC
contractor
Receive final comment from
EPC contractor

Prepare and Submit IFA Rev.A [Piping GA Drawings]

EPC Contractor Review [Piping GA Drawings]

Incorporate Comments & Submit IFC Rev.0 [Piping GA

Drawings]

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Engineering Work Flow-Process, Mech and Piping

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Engineering Work Flow –C&S, Mech and Piping

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Engineering Work Flow – E&I

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 Engineering Work Flow – Instrumentation

•Instrument I/O List

•Instrument Index

•Instrument Data sheet

•Instrument Hookup Diagram

•Instrument Loop Diagram

•Instrument Layout Diagram

•Cause & Effect Diagram

•Cable Schedule Diagram

•Project Interconnection Diagram

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 Engineering Work Flow – Instrumentation

I/O List is a contains list of instrumentation which serve as an input or output of control system. Hence the tag number that physically
has a cable which connects to the control system appears on I/O list.

Instrument index is a document containing list of instrument devices within a plant. Instrument index shall include tag number of all
physical instruments

I/O Count will determines the required capacity of a system

Reference Drawing
P&ID, HMB

Instrument Index
Reference Document
Cause & Effect

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 Engineering Work Flow – Instrumentation

Instrument Data Sheet is a document containing specification and information of an instrument device. It specifies general information
of instrument such as tag number identification, service description, location (line number/equipment number), P&ID number or
drawing number reference, process data (if applicable), calibrated range (if applicable), material, performance details (such as accuracy,
linearity – if applicable), hazardous certification (for electrical device), accessories required, etc. The details of information in data sheet
may differ among each types of instrument such as transmitter, switch, gauge, control valve

Once the data sheet completed, it is attached to requisition which to be sent to vendors. Vendors will offer their quotation with various model and
manufacturer among the offers.

Having been considered its technical and commercial aspects, the instrument is purchased. Following the purchase order, vendor will submit
supporting document and drawing. Based on vendor data, instrument data sheet may be updated to accommodate details to make the data sheet
“as-built”.

Reference Drawing
P&ID, HMB,

Instrument Data
Sheet
Reference Document
Instrument specification,
piping specification,
calculation, vendor
catalogue

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 Engineering Work Flow – Instrumentation

Hook-up drawing is a detailed drawing showing mounting and connection of instrument to process lines and corresponding list of
required material.

Hook-up drawing also gives information the requirement of bulk material for each installation. It also details its specification (size, type
and material) and the quantity.

There are two types of hook-up drawing:

1. Process Hook-Up
This hook-up drawing contains typical installations for instrument which connects to the process
1. Pneumatic Hook-Up

Reference Drawing
P&ID, Installation Detail
Hookup Drawing
Specification, Piping
Specification

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 Engineering Work Flow – Instrumentation

Instrument Layout is also known as instrument location plan. This drawing shows the exact position of each instruments with reference
to plant layout.

The point indication of instrument position and its mounting stand where instrument to be mounted and process tap
location.

Often the tap location and the instrument is separated quite distant. In some project, it is not mandatory to show the
process tap location

Reference Drawing
P&ID, Piping
Instrument Layout
Plan,piping GA and
ISO

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 Engineering Work Flow – Instrumentation

Cable Schedule is a document containing list of instrument cables to install, cable type, length, origin, destination and route.

Reference Drawing
Instrument Cable Layout,
Interconnection block
diagram
Cable Schedule
Reference Document
Instrument Index / I/O
List

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EPC Project Management
- Procurement Work Flow

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 Procurement Work Flow

Tender
Inquiry Purchasing Purchasing Received Approved FAT or Final
Evaluation Delivery at
issued to request order Key vendor key vendor Fabrication inspection Ex-work
and client site
bidders created placed drawings drawings finished
approval

General procurement work flow and how rule of credit being assigned to each step.

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Procurement Work Flow

Progress tracking sheet for procurement work flow

Procurement progress calculation excel sheets are available for download in ignite.com

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Typical On-Shore Project Schedule and
Dependencies

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 Typical Level 1 –On-Shore Project Schedule

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Work front Concept

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 Work Front

Engineering progress is commonly measured by assigning a weight, usually the required number of required manhours, to each
task/deliverable. Once the task is performed/ the deliverable is issued, the corresponding manhours are earned.

The earned progress divided by the total number of manhours gives the % progress.

As each engineering task/deliverable is scheduled at certain dates, it is possible to anticipate the progress that should be earned at a
given date. It is the planned progress.

At regular period, usually on a monthly basis, the actual progress of each activity/deliverable is measured against the planned progress.
An actual progress less than the planned progress might show a lack of resources and a need for increased mobilization to get back on
plan, following a (re-)forecast progress curve.

Although such progress measure is commonly used, it could be deceiving. It indeed reflects rather well the progress of engineering on
its own but not how well is engineering supporting the Project schedule.

Let’s consider that engineering must issue 2 material requisitions, an urgent one for a Long Lead Item and another one which is
required later on. Engineering will earn progress whatever requisition it issues, even if putting the Project in delay by issuing the non
urgent requisition first.

One sees that the above measure of progress alone is insufficient. It must be complemented by monitoring that important Milestones
are met.

These Milestones are first of all, the ones associated with the issue of the Requisition for the equipment. Long lead items have
naturally to be purchased early. All equipment and packages also need to be purchased as early as their technical definition allows.
Indeed, engineering development is highly dependent on information from vendors. The sooner the purchase orders are placed the
sooner the vendor information will be available.

Next come the Milestones associated with Bulk Material Procurement to support construction, such as the Piping MTO and the
Structural Steel MTO (for an off-shore Project).
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 Work Front

Then come the Milestones associated with Construction. These are the IFC Plot Plan, a pre-requisite to start any site work, and the IFC
P&IDs, a pre-requisite to the issue of Piping isometrics. The 50% IFC Piping isometric milestone comes next, which typically falls half way
through the Project, as ensuing works, such as pre-fab and erection have a rather incompressible duration, due to site constraints
(capacity of pre-fab shop, space constraints for erection limiting the progress).

Even if engineering deliveries are in sequence, the above engineering progress measure might still be deceiving, as it will only reflect
the amount of engineering work completed and not the workfront made available to construction.

Let’s consider for instance that two foundations are to be cast. The first one is a very large foundation and the second one a small one.
Issuing the drawing of either the large or small foundation will earn engineering the same progress, although it will open quite a
different workfront to Construction.

One sees the necessity to measure the issued Workfront.

In the case of foundations, for instance, this will be done by monitoring the cumulative quantity of concrete (m3) of all issued IFC
foundation drawings.

Producing an S curve, such as the one shown in next slide, showing both planned and actually issued quantities will give a true picture of
how well engineering is supporting civil works.

One will similarly monitor, for an On-Shore project, the cumulative quantity of steel (tons) of issued IFC Structural drawings.

The cumulative tons (or dia inch) of IFC issued Piping isometrics will show the available piping workfront.

Such progress curves, showing the actual versus planned available workfronts are instrumental to monitor engineering progress, identify
shortage and take corrective actions (increase mobilisation).

It is not perfect however and can still be deceiving, in case of out-of-sequence issues: engineering may have issued drawings
representing significant quantities, but that does not generate construction workfront as such works can not be performed at this time
(due to lack of access or pre-requisite for another work to be completed before, for instance).
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 Work Front

Construction work-front planning and forecasting processes allow Materials to gather construction work package requirements and
material situation throughout the supply chain with appropriate feedback into the EP process 51
Advanced Work Packaging

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 Work Face Planning

Path of
FIWPs
EWP CWP
Construction

500 – 1000mhrs

System turn-over drives Construction

Construction drives Engineering & Procurement

EWPs(Engineering Work Packages) are Engineering deliverables

CWPs (Construction Work Packages)& FIWPs (Field Installation Work Packages) are Construction deliverables

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 Work Face Planning

EWPs (Engineering
Work Packages) set
the precedence for
Construction work.

Using the P&IDs (for item count) and Piping Layout Drawings (for lengths) a preliminary list for piping material requirement generated
which known as piping MTO (piping material takeoffs)

The GA drawing used for pipe erection while the piping ISO are used for pipe prefabrication.
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 Planned Path in Construction Work

Work commences
9 weeks lag
Engineering Work Package (EWP) Construction Work Package (CWP)

Engineering’s Bill of Material

Procurement Package (PP)

Equipment / Material arrives prior

Purchase Order to supplier to work commencing

Supplier Equipment / material

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 Planned Path in Construction Work

1 2 Contractor resource mobilized

Forecasting to meet scheduled IFC

Work commences
9 weeks lag
Engineering Work Package (EWP) Construction Work Package (CWP)

Engineering’s Bill of Material

Procurement Package (PP)

Equipment / Material arrives prior

Purchase Order to supplier to work commencing

Supplier Equipment / material

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 Constrained Path of Construction

2 Contractor resource mobilized

Lag gets squeezed CWP starts late Work commences

9 weeks lag
Engineering Work Package (EWP) Construction Work Package (CWP)

Vendor Data needed to complete

Procurement Package (PP)
EW delivered late or incomplete

Equipment / Material arrives prior

Purchase Order to supplier to work commencing

Supplier Equipment / material

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 Constrained Path of Construction

2 Contractor resource mobilized

Work commences

Engineering Work Package (EWP) Construction Work Package (CWP)

How do we improve this interface?

Procurement Package (PP)

Purchase Order to supplier

Supplier Equipment / material

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 Constrained Path of Construction

Work commences
Delay in Engineering will cause lag gets squeezed CWP
starts late
Engineering Work Package (EWP) Construction Work Package (CWP)

Model Review causes late changes

MTO can’t be created

How are these mitigated /
eliminated?
No IFC or AFC status for P&IDs

Specification is not complete

It is important to knows
the work sequence in order
Client or EPC take longer time for document review and caused delay
to plan for Construction
Work Package.

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 Engineering Work Package Progress

Ex : Piping Work Package.

1 3D modelling development

2 P&IDs

3 Requisitions

4 Specifications.

5 Pipe Stress analysis

6 Calculations

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Forecasting Scenario

Ex : Piping Work Package.

EWP is forecast to meet scheduled IFC

Contractor plans resource mobilization

Next Weekly Forecast - EWP slips one week

Contractor tries to mitigate

Next Weekly Forecast - EWP slips another week

Delay in Construction work and recovery needed

Delay in Engineering Work

Package approval in return cause
delay in construction work.

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 Potential Work Flow and Rule of Credit for Piping

Step Work Flow Increment % Cumulative %

1 EWP ID’d and mapped to CWP 5% 5%

2 Initial scope identified (line numbers) 15% 20%
3 Preliminary equipment data received 5% 25%
4 Initial routing of lines established 20% 45%
5 Initial bulk material (BOM) to supply chain 10% 55%
6 Piping studies rec’d for critical lines: 5% 60%
7 Final vendor data received 10% 70%
8 Final routings completed 5% 75%
9 P&IDs and LDT issued IFC 5% 80%
10 Stress analysis for large bore completed 5% 85%
11 BOM completed 5% 90%
12 EWP c/w all drawings/specs issued IFC 5% 95%
13 EWP accepted by Construction AFC 5% 100%

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 What Makes Forecasting is a Challenge

EWP process has many steps to get to IFC

The rules of credit (if they exist) are either not known or not utilized.

EWP development held back by outside influence

(e.g., Systems, Vendor Data or Owner Decisions)

Challenges
Construction mobilizes resources based on forecast completions of EWP IFC

Engineering forced to release partial EWPs or releases EWPs out of sequence or

EWPs with HOLDS

EWP releases continue to slip but construction is now mobilized

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 Engineering Work Package and Construction Work Package

CWP
Engineering Procurement Construction

Scope of Work HSE/Safety

IFC drwgs Eng.Specs&Stds Manpower req.
Equipment/Materials Level 4 Schedule
Long Leads RAS dates
Vendor info QA/QC
Material Mgmt Expediting
Quality Instructions Construction Tools/Equip
Transportation Special
Regulatory Heavy Lift Plans
Requirements
approvals/permits Scaffold
Turnover Documents Waste Mgmt
Schedule (Level 5) Interfaces/Coordination

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Sample WBS

65
WBS Structure

66
WBS Structure

67
Sample WBS for Electrical Construction

68
Sample Pipeline Construction Project WBS for Refinery/Chemical Plant

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 Sample Pipeline Construction Project WBS for Refinery/Chemical Plant

Sample WBS for piping construction project for a refinery or chemical plant may be organized as the following.

It is worth to be organized by location wise (i.e. platform and pipe rack, platform and equipment around piping) prior to “Phase” WBS.
Timely completion of piping construction is not only depending on timely receiving of engineering drawings and materials from Owner/EPC
contractor but timely availability of the infrastructure should also be addressed. Sometime it refers to work front availability.

Developing WBS is mainly depending on the project scope. It should be defined according to the project specific as every project is different,
for instance, “Demolishing” WBS may also be added under “Phase” level priority to “Installation” WBS if your project scope involved a
considerable amount of piping demolishing scope. “Above Ground” and “Under Ground” WBS can be left in case no underground piping work
is
included in the project.

(1) Level 1: Plant Unit, e.g. Utility Unit, Ethylene Theatre Unit, etc.

(2) Level 2: Area within a Unit, for instance, Area ABC, Area XYZ. Area demarcation is marked for a group of process piping on above
ground and underground.

(3) Level 3: Height. This is to segregate pipe work on the above ground and underground.

(4) Level 4: Location where pipeline is run, for instance, piping on and around pipe rack, equipment and equipment platform.

(5) Level 5: Phase, e.g. Fabrication, Installation (field erection, NDT) and pre-commissioning (hydro testing, air flushing, chemical cleaning
etc.)

Note :

“Common” WBS name refers to common location where interconnecting piping is running between the pipe rack and equipment
or equipment platform. Having a clear definition of what is and what is not meant by “Common” is important

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 Sample Fuel Tank WBS

External Floating Roof Tank

0

Foundation work Field erection works

1.0 2.0

Tank accessories Fire fighting

Tank Bottom Shell side Roof works
installation works
2.1 2.2 2.3
2.4 2.5

Bottom plates Shell plates Center deck plate Internal Foam piping
installation installation installation Appurtenances installation
2.1.1 2.2.1 2.3.1 2.4.1 2.5.1

Nozzles and man External

Final coating Drainage piping Final coating
ways installation accessories
2.1.2 2.3.2 2.5.2
2.2.2 2.4.2

Final Coating Final Coating

2.2.3 2.3.3

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Sample Fuel Tank WBS

72
 Piping Discipline
( Piping Fabrication, Tie-in and Commissioning )

73
Piping Tie-in Process

Normally, piping tie-in installation scope is involved in revamp project only. The progress tracking system for tie-in work includes Tie-in
Tracker Sheet and Progress tracking sheet.

Tie-in numbers against the Isometric drawings and work packages are listed in the tracker sheet. The tie-in type (Bolt-up, cut and
weld, hot tap, cold tap and threaded are typical tie-in types in process industry), project area or system name and installed dates are
also included in the tracker sheet.

To develop Progress Tracking Sheet for overall Isometric drawings, the following work steps and weight factor percentages are utilized.

1. Preparation ( Scaffold erection if required/remove insulation if required) -20%

2. Tie-in work (Bolt up/cut & weld/hot tap/cold tap/threaded) -70%
3. Inspection (Sign QC document, example : flange make up check list) -10%

The Progress Tracking System for Pipeline Erection Work

Developing procedure of progress tracking system for pipeline erection work is the same as piping fabrication work except work steps
and weight factor percentages. To do that, replace the following work steps and weight factor percentages with the existing ones and
rearrange the formulae.

1. Material at Erection area - 5%

2. Piping Laying -20%
3. Preparation(align/tack weld) -20%
4. Full Welding Execution - 40%
5. Non Destructive Examination - 5%
6. Pipe Support Erection -15%
7. Final Inspection - 5%

74
Commissioning Test package and Tie-In

Piping Fabrication

Piping Tie-In System

Commisionning

Piping Test Package

75
 Piping Tie-in Work Sequence

Weld map Spool Surface

Withdrew Welding Final Delivery at
drawing assemble and Welding NDT preparation
material preparation inspection site
preparation tack weld and coating

General piping tie-in work flow and how rule of credit being assigned to each step.

76
 Piping Hydrotest Work Sequence

Preparation Done Testing Reinstated Clear Punch list

General hydrotest work flow and how rule of credit being assigned to each step.

77
 Commissioning Test package and Tie-In

Tie-In List Test Package for Pre- Commissioning

78
Piping Tie-In

79
Special Pipe Support Drawing

80
Piping Pre-Fab Drawing

81
Piping ISO Drawing

82
Vessel Fabrication

83
 Vessel Fabrication Work Flow

Exchanger Vessel Exchanger Vessel

Tubesheet Fit Up Testing (NDE,
Fit Up (Pre- Weld Out Painting Ex-work
/ Weld Out Hydro
Fabrication) (Assembly)

84
Vessel Fabrication Work Flow

Shell Side Fabrication

Dished head Installation
· Plate marking /cutting/ beveling and inspection
· Fit up and tack weld/Inspection – Dished head to shell
· Shell plate rolling work
· Full circumference welding
· Longitudinal steel (LS) fit-up and inspection
· Inspection for full welds (NDE)
· LS welding and inspection (NDE)
· Circumference steel (CS) fit-up and inspection
· CS welding and inspection (NDE)

Inspection (Hydro-testing)
Inlet and outlet nozzles fabrication
· Hydrostatic testing
· Pipe marking/cutting / beveling and inspection
· Draining/drying and final inspection
· Fit-up and welding of flanges and pipes
· Inspection for nozzles to flange joints (NDE)
Blasting and Painting
Nozzle Attachments to Dished Head
· Blasting/Inspection
· Marking of nozzle location on dished head · Primer/Final coating/Inspection
· Cutting/opening/ beveling and inspection
· Fit-up and tack weld nozzle to dished head
· Inspection for tack welding (if required)
· Full weld - nozzle assembly with dished head
· Inspection for nozzle to dished head welds (NDE)
Nozzles and other accessories to Shell

· Marking of nozzles location

· Cutting/opening/ beveling and Inspection
· Fit-up and tack weld nozzle assembly to shell/inspection
· Full weld - nozzle assembly with shell
· Inspection for nozzle to shell side welds (NDE)
· Fit up and welding for instrument attachments
· Fit up and welding for lifting lugs

85
Vessel Fabrication Case Study

86
Vessel Fabrication Process

87
Plate Cutting

88
Plate Rolling

89
Longitudinal Seam Welding

90
Longitudinal Seam Welding

91
Can to Can Fit-up

92
Can to Can Fit-up

93
Can to Can Fit-up

94
Tack Weld

95
Weld Inside Circumference of Can

96
Weld Outside Circumference of Can

97
Weld Outside Circumference of Can

98
NDT

99
The End

101