Professional Documents
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Projects
This chapter discusses project types and project phases. I keep these
subjects as simple as possible, because no two projects are the same,
but all have a beginning, a middle, and an end. I will avoid discussing
in depth numerous possibilities that can happen during a project.
A project that requires process piping systems can be divided into two
types of construction, either grass roots or Brownfield.
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158 Chapter 5-Projects
Hydrocarbon refining.
Oil and gas separation.
Ammonia production.
Aromatics production.
Benzene production.
Butadiene production.
Crude oil refining (see Figure 5-1).
Ethylene production.
Fertilizer manufacturing.
Changing gas to liquids (GTL).
Gasoline blending.
Liquefied natural gas (LNG) production.
Paint manufacture.
Polyethylene production.
Sulfur recovery.
Water treatment.
Waste treatment.
Sewage treatment.
Pulp paper manufacture.
Air separation (oxygen, nitrogen, helium, argon).
Chlorine production.
Beer distilling.
Food processing.
A project takes several phases, regardless of the size and the com-
plexity of the process:
Feasibility.
Conception.
Detailed engineering.
Construction.
Commissioning.
Feasibility Phase
For the piping group, the major deliverables during this phase are as
follows. The piping material engineering group prepares a prelimi-
nary list of piping classes and preliminary technical piping specifica-
tions. The piping design group prepares preliminary piping design
specifications and piping studies.
At this stage, piping drawings and documents are issued for approval.
For the piping group, the major deliverables during this phase are as
follows. The piping material engineering group prepares
There are other variations, but these are the two most common. They
can be awarded to one company or, what is more common on larger
projects, a consortium of specialist engineering and construction
companies. The latter spreads the responsibilities and risks of the
project to a consortium of contractors.
For the piping group, the major deliverables during this phase are as
follows. The piping material engineering group issues
as well as assembles stress packs (IFC) and reviews and approves con-
cession requests regarding piping stress issues. The piping material
control group issues
Acceptance criteria.
Certification requirements.
The fabrication of piping spool usually takes place at the job site or a
location very close to it, to reduce the transportation costs and sim-
plify the logistics. IFC isometrics are issued by the EPC contractor
responsible for the detailed design and sent to the piping fabricator,
who is often a subcontractor.
5.2 Project Phases 167
Assume all the piping material and the isometrics have arrived and
the spool is fabricated but it is not in line with the construction
sequence. For a certain period this can be acceptable, because spools
can be stored for a period of time, but there is a limit to the space
available. The ideal situation is that, once a spool has been fabricated
and passes all the nondestructive examination tests, it should be
transported to site immediately and installed as quickly as possible, in
line with the construction sequence.
Piping systems in a specific unit or area are tested until all the systems in
the unit or area are mechanically complete and the project can move to
the commissioning phase. Mechanical completion occurs when
For the piping group, the major deliverables during this phase are as
follows. The piping material engineering group prepares
The piping design group prepares a piping CAD 3D model and the
piping isometrics (IFC). The piping stress group prepares a Piping flex-
ibility analysis for critical lines (IFC) and the stress isometrics (IFC)
and assembles stress packs (IFC). The piping material control group
prepares top-up material takeoffs for requisitions (IFC) and the con-
trol reports of piping materials delivered to the site (IFC).
5.2 Project Phases 169
Commissioning can start at the tail end of the detailed design phase,
when lead piping engineers and key personnel are still working on
the project and are available to answer any technical questions.
When all the units and areas have been successfully commissioned,
before startup and handover to the operator/end user, the plant has
to successfully complete a performance test for a fixed period of time.
At this stage of the proceeding, the detailed design phase for the
piping group will have been closed out, and the only personnel left in
the design office will be project engineers.