OVERALL EPC SCHEDULE - METAL PROCESSING PLANT
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Sl.
Activity Description
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A
1.0
New Plant EPC Build
Engineering Basic Engineering Finalise Conceptuals/ Process Configs Schedule B Pkg -- Heat & Mass Balance Study -- Hydraulics -- Equipment Datasheets -- Utility Summary -- Process - PFDs -- Process - P&IDS Detail Engineering Sys. & Loss prevention- PFDs / Hazops Mechanical - MR & Vendor Data Plant Layout & Piping MTOs 3D Model Isometrics Civil/Strl/ Arch. Drgs Electrical - SLDs / drgs Control Systems ( Inst) drgs
Grading drgs Compl. SLD (IFD) PMTO PMTO SLD(IFC) Prelm.MTO Start 3D Model Start Isos Prepn. Compl.Piperack drg Inter. MTO Inter. MTO P&ID-IFA Critical MRQ P&ID-IFM Critical MRP Plot plan -IFD Major NOA Initial VI Plot plan -IFC Intermediate MTO Compl. 3D Model 50% Isos LB Compl.Major Fdn drg Set route cables/conn.drg Final MTO Final DCS d/base 90% Isos LB Bal Fdn Drgs Compl. Major PEL l/o Final loop drgs Field Engg & Top-off MTOs Field Engg & Top-off MTOs Compl. SB Isos Final MTO Final Configs
Start Issue PFDs
Compl PFD
Compl.Hazop P&ID-IFD Final VI Minor VI P&ID-IFC
2.0
Procurement EPC Package Fired-Heaters Tagged Items Super ODCs Columns Vessels / Drums Reactors Compressors Pumps Exchangers/Air Coolers Filter/Strainers Special/design piping items Transformers Panels CVs/RVs/MOVs/IsolVs . ISBL - Package Units Bulk Items Civil - Cement/Torr. Strutural Steel Plates Piping - Pipes/fittings/valves Electrical- Cables Instrumentation - Cables
Compl MRQ issue Compl. NOA Compl VI Start Delv. Compl Delv Compl E&C
Compl MRQ issue Compl MRQ issue Compl MRQ issue Compl MRQ issue Compl MRQ issue
Compl. NOA Compl. NOA Compl. NOA Compl. NOA Compl. NOA Compl MRQ issue Compl VI Compl VI
Compl VI
Start Delv. Start Delv. Start Delv. Compl Delv Compl Delv
Compl Delv
Compl VI Compl VI Compl. NOA( Crit.pumps) Compl VI Compl. NOA Compl. NOA Start Delv. Start Delv. Bal.NOA Compl VI Start Delv. Start Delv. Compl Delv Compl Delv
Start Delv. Start Delv. Compl Delv Compl Delv
Compl Delv Compl Delv
Compl MRQ issue Compl MRQ issue Compl MRQ issue Compl MRQ issue Compl MRQ issue
Compl. NOA
Compl. NOA Compl. NOA Compl MRQ issue
Compl VI Start Delv. Compl. NOA Compl VI Start Delv. Start Delv. Compl Delv
Start Delv.
Compl Delv
Compl MRQ issue
Compl. NOA
Compl Delv
Start MR Start MR Start MR Start MR SO
SO
Start Delv SO SO Start Delv Start MR Start MR SO SO Start Delv Start Delv Compl MR Start Delv Compl.MR
Compl.MR Compl.MR FO FO Compl.MR Start Delv Compl.MR
FO FO
Compl.Delv. Compl.Delv. Compl.Delv. Compl.Delv. FO FO Compl.Delv. Compl.Delv.
3.0
Construction Site Preparation Civil Works - Fdns/RCC works. Buildings - S-Stn/PIBs/Ctrl room/Offices Structural Works Fabrication Erection Equipment Erection Fire proofing Fired Heaters Tankage works U/g works - trenching/piping etc. Piping Pipe fabn - Shop Field piping Electrical works Instrumentation works Insulation Painting
Start Heavy Lift Erecn
Compl.Heavy Lift Erecn
ISBL
OSBL
4.0 Start-up
Precomm - Loop checks Comm.- Hook-up/ System integration RFSU Indicative % Engg. Progress (Cum) Indicative % Procurement Progress (Cum) Indicative % Construction Progress (Cum) Indicative % Overall Progress (Cum) 0.4 3.6 0.2 2.1 1.2 6.2 0.8 3.8 4.0 11.0 1.7 7.0 8.1 16.0 3.3 10.8 13.6 25.1 5.2 17.0 20.1 34.1 7.7 23.5 27.8 41.7 11.4 29.7 35.2 47.9 16.0 35.5 43.4 52.7 21.5 40.8 52.2 56.4 27.5 45.8 61.0 60.1 34.1 51.1 69.3 63.2 41.0 56.0 77.4 65.9 48.3 60.9 83.9 69.4 55.4 66.0 88.9 73.3 62.5 71.1 92.9 77.8 69.0 76.2 95.7 81.8 75.0 80.8 97.5 85.5 80.4 84.9 98.6 88.8 85.6 88.6 99.3 92.0 90.3 92.1 99.5 93.8 93.6 94.3 99.7 95.0 96.3 95.9 100.0 96.3 98.1 97.3 100.0 97.1 98.3 97.8 100.0 97.9 98.6 98.3 100.0 98.4 99.0 98.8 100.0 99.2 99.3 99.3 100.0 100.0 99.6 99.9 100.0 100.0 100.0 100.0
M-1
M-2
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M-5
Milestones & Check-Points across Project Execution for System Driven Commissioning
Milestone
Engineering
M1
Milestone Physical Indicator
Procurement Construction
Site Preparation under Progress
% Progress Indicator
E
30%
Milestone Check Points
Engineering
Sequence for Overall Plant Start-up finalised
P
40%
C
10%
Total
30%
Procurement
Construction
Basic Engineering Completes Major Long Lead Items Ordering starts
Critical Long Lead equipment ETA is Detail Construction lookahead plan finalised basis alignment with gets finalised based on process finalised start-up sequence sequence. Subsequent Bulk Item Ordering follows the same logic
3D Modelling Starts
Sourcing Plan for Bulk Material Civil Contractor mobilised gets finalised
Agreement obtained from EPCO team Same logic is applied for plant mechanical modeliing
Plot Plan is IFD M2 3D Modelling is 30% Long Lead Ordering Completes & vendors given advance Civil foundation & superstructure work starts 60% 60% 35% 50%
First Model review with Constn. & Ensure Long Lead Equipment are on Detail Civil work liquidation plan Opn. for constructability & operability schedule and all vendor interface / prepared & actualised as per actual clashes are resolved. progress. Any clash in constn. expectation / process sequencing is duly addressed. Process Battery Limits & Interfaces are clearly identified. Sequence Bulk material delivery to Mechanical Contractors are prioritise Bulk commodity liquidation appraised about front availability forecast & interface needs
Plot Plan issued IFC
Bulk Material Delivery Starts at Underground works start site Mechanical works contractor are aligned Long Lead Item shop Inspection starts Steel Structure Works Starts 90% 75% 65% 70%
Equipment Vendor Drawing review starts M3 3D Modelling Completed
Final model review is done and complete alignment between EPCO team is ensured IFC deliverable of All discipline must show battery limit / process interface
Re-align major equipment despatch schedule with system start-up sequence and inform vendor
Detail Mechanical Work completion plan is prepared and alignment with system start-up target ensured System driven pre-commissioning & handover plan prepared. Utilities, Consumables & P&M are estimated. E&I contractor is appraised about front availability & completion / charging target. Closely co-ordinate between discipline contractor for timely erection of Critical equipment. Ensures hook up of elements with installed equipment just after erection completion. Mechanical completion task force is formed and resources & utilities are made ready. Expedite delivery of mechanically completed system to operation. Mutual walk through of operation to identify & liquidate punch points.
All vendor data are validated & Bulk item ordering completes included in design
Piping (A/G, U/G) work starts
Major discipline IFC deliverable issue neras completion M4 IFC deliverable issue completed
E&I contractor gets mobilised
Detail System definition and commodity wise scope are prepared 100% 96% 98% 97% Field engineering set-up ready for Mobilisation of Equipment Vendor quick response regarding schedule Rep. / Technology providers Rep. improvement solution thru innovative starts as per Start-up sequence construction. Physical / walk through audit starts for ascertaining critical interface / battery limit physical completion Spares & Consumables, Critical Tools & Tackles required for Mech. Completion are identified and availability ensured at site
Long Lead items starts arrival Mjor Civil, Structural, at site Mechanical works are complete Bulk Item receipt completed E&I work under progress
Engineering Package transferred to field
Filed engineerig starts
Critical equipment erection starts Equipment Order Close out process starts System Mechanical completion & handover to operation starts Trial run of equipments start 100% 99% 99% 99% System dossier need to be prepared Commercial documentation with certified acceptance record for completion is ensured. custody transfer.
M5
As built Starts
Ensures system dossier handover to concerned O&M group
