Oil & Gas Plant Construction, Project Execution Plan

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 and controlled. Also the measures to
ensure that the site is environmentally friendly.
http://www.slideshare.net/DavidHMoloney/oil-gas-plant-construction-project-execution-plan
https://www.youtube.com/watch?v=PiRY0ERoXfI
6avid H Moloney
4th August 2016
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.

Gas Processing Facility
Earthworks includes Excavation, Trenches, Haulage, Grading Backfilling, Filling & Compaction
Earthworks

Trench Excavation with Stepped Faces

Trench Excavation with Battered Faces

Spreading & Compaction Clay fillEarthworks

Dozer Ripping GroundEarthworks

Excavator with Hydraulic RockbreakerEarthworks

Excavate & Load, Cart, Tip & Return
Brief Description
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
Earthworks
7 minutes
14 minutes
3 minutes
14 minutes 7 km
7 km

CABC ( Crushed aggregate base course )
Earthworks
Mixing Plant
Testing Compaction
Site Trial

Spreading & Compaction CABC ( Crushed aggregate base course )
Earthworks

Spreading & Compaction CABC ( Crushed aggregate base course )Earthworks

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

Insitu Piling Construction - Plant & Methods
3D image to show Plant.
For construction details see my YouTube Channel
Plant & Equipment
Crawler Crane
Piling Hammer
Casing
Piling Rig
Concrete Pump
Concrete Mixer Trucks
Tremie Pipe
Reinforcement Cage

Piling Construction - Plant, Methods & SequencePiling

Piling Construction - Plant & MethodsPiling

Pile Load Test
ⓒ David H Moloney
Piling

Sheet Pile Shaft Temporary to Support Excavation
Drive Sheet Piles Excavate & install bracing
Construct Concrete Structure Backfill, remove bracing & sheet piles
ⓒ David H Moloney

Sheet pile Temporary Shaft
ⓒ David H Moloney
GeneralItems
3D Animation to show Sequence

Secant Pile Construction - Sequence, Plant & Methods
3D image to show Sequence, Method & Plant.
ⓒ David H Moloney

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

Jetty for Oil Tankers
ⓒ David H Moloney
Marine

Quay Wall
ⓒ David H Moloney
Marine

Breakwater
ⓒ David H Moloney
Marine

Dredging & Reclamation
ⓒ David H Moloney
Marine

Reinforced Wall Construction Sequence
ⓒ David H Moloney

Reinforced Wall Construction Sequence
ⓒ David H Moloney
Concrete

Reinforced Structure Construction Sequence
ⓒ David H Moloney
Concrete

Reinforced Construction Tank Sequence David H Moloney
ⓒ David H Moloney

Oil Interceptor
Miscellaneous
Used to capture oil / fuel from leaks or spillages that are washed down
drains every time it rains.

Excavation for Underground Pump stationEarthworks
Brief Description
Faces of excavation Stepped &
Well-point Dewatering used.

Main Equipment
Path of Construction 45
Slug Catcher
Generators – Gas Turbine Flares
Liquid Train Gas Train Compressors

The Pipe Racks carries pipes and cables.
The pipes contain gas and liquids that are transported to and from the
different processes.
Pipe Rack

Piperack Construction Animation
The Pipe Racks carry pipes and cables
between the different processes..

Hanging Scaffold
Stairway Tower
Pipe Rack – Scaffold Underslung

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

Slug Catcher Construction Sequence Animation
Separates the Gas from the Oil & Water
Also to dissipate any pressure surges

Storage of Oil & Water
Steel Circular Tanks Construction

Steel Storage Tank
ⓒ David H Moloney
StructuralSteel

Steel Circular Storage Tank – Construction ⓒ David H Moloney

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.

Spool Fabrication in Workshop
Pipework

Spool Fabrication on site
Pipework

Post Weld Heat
Treatment
Non Destructive
Testing
Cut
Bevel
Fit-up
Weld
NDT
PWHT
Blasting
Painting
Spool Fabrication Steps

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

Erect Flares / Columns & Vessels

Cranes Heavy Lift Animation
Lift column from the horizontal and
rotate into the vertical

Erect Flares / Columns & Vessels - 3D Simulation

Flares / Columns / Vessels Erection
Path of Construction 74
Demag CC180-1 300 t crawler crane
72m boom & 42m luffing jib
Tandem Lift to tilt flare
from horizontal to vertical
Trunnions
Main
Lift
Crane
Tail
Crane

Electrical Sub Station 3D Model
3D Model – Used to provide a better understanding

Main Substation Horizontal Cross section
Transformer Bays
HVAC Room
Heat, Ventilation, & Air Conditioning
Battery Room
UPS
Room
Local
Equipment
Room
Chillers

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.
ⓒ David H Moloney
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

Steel Building Single Storey
ⓒ David H Moloney
StructuralSteel

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

Roof Covering
ⓒ David H Moloney
StructuralSteel
Brief Description
Sequence is
Fix bottom sheet
Fix Vapour barrier
Fix Top Hat section and clips
Fit Insulation
Fix top sheet

Roof Covering
ⓒ David H Moloney
StructuralSteel

Onshore Gas Pipeline Construction Sequence

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
Hydrotest & Pigging
Tie-in i.e. connect to existing pipeline
Miscellaneous
Pause Slides to Read

Overview Pipeline Construction Animation
To see animations, view YouTube film.

Cable Laying
Pipework
Brief Description
132 kVa Cable laying .

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 Sequence David H Moloney
ⓒ David H Moloney
Tunnels

Includes Sequence, Methods & Equipment
Road Construction

Road Construction Sequence Animation

Includes Sequence, Methods & Equipment
Fencing & Gates

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

Emergency Phone Numbers & Response
Health,Safety&Environment

HSE Monitoring & Reporting - Dashboard Dashboard is a single page, graphical representation of
current HSE Issues and historical trends

Safety Precautions

Safety Documents
Safe System of Work.
To provide a safe system of work is a legal requirement. What this means is that before you ask an employee to do a
job. You ensure that he has received training, has the appropriate personal protective equipment, the work area is safe
and he is unlikely to be injured or cause damage by carrying out the assigned task.
Project Management Plan for Health, Safety, Security and Environment. also Known as (HSSE Plan)
The Project HSSE Management Plan details how safety on site will be managed.
Project Procedures for Health, Safety, Security & Environment
Details the safe way to undertake a task
Methods Statements
Are prepared in advance of starting work, to plan a Safe System of Work on site for all activities that carries a risk. The
contents of a Method Statement, typically include:- Scope & Location of the Works, Programme, Roles & Responsibilities
of Staff. Resources, Work Methodologies and Risk Assessment.
Slide 1 of 2

Safety Documents
Safety Risk Assessments
Are prepared to identify and evaluate risks, to adopt control measures to reduce or eliminate risks.
COSHH Sheet
The purpose of the Control Of Substances Hazardous to Health sheet is to identify how to prevent or adequately control
workers exposure to hazardous substances.
Permit to Work.
Is a management system used to control high risk activities by ensuring safety measures are in place prior to starting
work.
Types of work for which permits will be required include:
Excavation and the digging of trenches.
Working at height, including on roofs.
Working in confined spaces, for example entering a manhole.
Hot work, which is welding, soldering or cutting steel with angle grinders or by gas torch.
Slide 2 of 2

Safety Training on Site
Miscellaneous The purpose of safety training is to provide the knowledge necessary to
perform a job safely

Safety Training Matrix
Miscellaneous The purpose of safety training is to provide the knowledge necessary to
perform a job safely

Emergency Response Drill
HSE
Drills and exercises are used to rehearse anticipated emergency scenarios

Exposed Existing Underground Utilities
ⓒ David H Moloney

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

Trench - Safety Measures

Trench - Safety Measures
ⓒ David H Moloney

Site Safety Posters examples

Personal Protective Equipment (PPE)
Personal protective
equipment (PPE) is
protective clothing,
helmets, goggles, or other
garments or equipment
designed to protect the
wearer from injury or
infection

Environmentally Friendly Site Air, Noise, Water & Soil PollutionHealth,Safety&Environment

Water Pollution PreventionHealth,Safety&Environment

Segregation of WasteHealth,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

Putting Waste Concrete to use
ⓒ David H Moloney
Health,Safety&Environment Precast bases for signs and hoarding,
Precast blocks for walls.

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.

Quality Assurance Dashboard Dashboard is a single page, graphical representation of
current statistics and historical trends

Progress Monitoring & Reporting - Dashboard
ⓒ David H Moloney
Dashboard is a single page, graphical representation of current progress and historical trends

Programme for Construction
Gantt Charts to plan and schedule projects

Primary Substation-
Chiller Plant
Pump House
IRRIGATION WATER TANKS
Irrigation Pump House-
POTABLE/FIRE WATER TANK
Programme using Timeline & 3D Images
Airport Central Utility Yard

Primary Substation-711
Chiller Plant-714
Pump House-
715
716

Chiller Plant-714
Pump House-
715
IRRIGATION WATER TANK
716

Chiller Plant-714
Pump House-
715
IRRIGATION WATER TANK
716
POTABLE/FIRE 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

Temporary Contractors Site Facilities
ⓒ David H Moloney
Brief Description
Site Offices, Camp Accommodation for
1,250 workers, Canteen, Recreation,
Fabrication shops, Stores, Plant Yard. In five
locations along the route.

Wheel Wash Drive-throughGeneralItems

Weighbridge & Sheeting Access
ⓒ David H Moloney
GeneralItems Access tower for covering tipper truck bodies to
prevent air pollution.

Dewatering
ⓒ David H Moloney
GeneralItems
Brief Description
Construction dewatering is the removal or
drainage of groundwater and or surface /
rain water usually by pumping to keep the
works dry.

Quarry & Aggregate Production
3D image to show Sequence, Method & Plant. ⓒ David H Moloney
Rock is blasted free from a
quarry face and fragmented.
The blasted rock is crushed and
screened to produce different
size ranges of aggregates

Quarry & Aggregate ProductionGeneralItems

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 Yard 3 Nr MixersGeneralItems

Concrete MixGeneralItems
A concrete mix contains 5 major
elements: cement, water, coarse
aggregates, fine aggregates (sand) and
air in different proportion. Additional
elements such as pozzolanic materials (fly
ash, silica fumes or slag) and chemical
admixtures can also be incorporated to
the mix to increase its properties.

Reinforcement Cutting & Bending Yard David H Moloney
ⓒ 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

Production by David H Moloney
My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ
ⓒ David H Moloney

Oil & Gas Plant Construction, Project Execution Plan

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