David H Moloney
Oil & Gas Plant Construction 2nd August 2016
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.
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.
Table of Contents
Contents
Earthworks
Earthworks includes Excavation, Trenches, Haulage, Grading Backfilling, Filling &
Compaction
Gas Processing Facility
Trench Excavation with Stepped Faces
Trench Excavation with Battered Faces
Earthworks
Spreading & Compaction Clay fill
Earthworks
Spreading & Compaction Clay fill
Earthworks
Excavate & Load, Cart, Tip & Return
Brief Description 7 minutes
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
7 km
14 minutes 7 km 14 minutes
3 minutes
Earthworks
CABC ( Crushed aggregate base course )
Testing Compaction
Mixing Plant
Site Trial
Earthworks
Spreading & Compaction CABC ( Crushed aggregate base course )
Earthworks
Spreading & Compaction CABC ( Crushed aggregate base course )
Earthworks
Spreading & Compaction CABC ( Crushed aggregate base course )
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
Contents
Insitu Piling Construction - Plant & Methods
Plant & Equipment
Crawler Crane
Piling Hammer
Casing
Piling Rig
Concrete Pump
Concrete Mixer Trucks
Tremie Pipe
Reinforcement Cage
3D image to show Plant.
For construction details see my YouTube Channel
Piling
Piling Construction - Plant, Methods & Sequence
Pile Load Test
Piling
ⓒ David H Moloney
Sheet Pile Shaft Temporary to Support Excavation
ⓒ David H Moloney
Drive Sheet Piles Excavate & install bracing
Construct Concrete Structure Backfill, remove bracing & sheet piles
Secant Pile Construction - Sequence, Plant & Methods
For construction details see my YouTube Channel
3D image to show Sequence, Method & Plant.
ⓒ David H Moloney
Diaphragm Wall Construction - Sequence, Plant & Methods
For construction details see my YouTube Channel
3D image to show Sequence, Method & Plant.
ⓒ David H Moloney
Contents
Jetty
Marine
ⓒ David H Moloney
Quay Wall
Marine
ⓒ David H Moloney
Breakwater
Marine
ⓒ David H Moloney
Dredging & Reclamation
Marine
ⓒ David H Moloney
Contents
Reinforced Wall Construction Sequence
3D image to show Sequence, Method & Plant.
ⓒ David H Moloney
Reinforced Wall Construction Sequence
Concrete
ⓒ David H Moloney
Reinforced Construction Tank Sequence David H Moloney
ⓒ David H Moloney
Oil Interceptor Used to capture oil / fuel from leaks or spillages that are washed down
drains every time it rains.
Miscellaneous
Oil Interceptor
Concrete
Earthworks
Excavation for Underground Pump station
Brief Description
Faces of excavation Stepped &
Well-point Dewatering used.
Contents
Main Equipment
Slug Catcher Flares
Generators – Gas Turbine
Path of Construction 35
Liquid Train Gas Train Compressors
Pipe Rack
The Pipe Racks carries pipes and cables.
The pipes contain gas and liquids that are transported to and from the
different processes.
Piperack Construction Animation
The Pipe Racks carry pipes and cables
between the different processes..
Pipe Rack
Pipe Rack - Expansion Loop
39
Pipe Rack – Scaffold Underslung
Hanging Scaffold
Stairway Tower
Gas Processing Facility
Pipe Rack under construction
Slug Catcher
The slug catcher buffers the incoming gas and liquid, from the wellheads, it
also separates the gas from the liquid.
Slug Catcher Construction Sequence Animation
Separates the Gas from the Oil & Water
Also to dissipate any pressure surges
Slug Catcher
Steel Circular Tanks Construction
Storage of Oil & Water
Steel Storage Tank
Structural Steel
ⓒ David H Moloney
Steel Circular Storage Tank – Construction ⓒ David H Moloney
Contents
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.
Pipe Spools examples
Spool Fabrication on site
Pipework
Spool Fabrication Steps
NDT
Cut Non Destructive
Testing
Bevel PWHT
Post Weld Heat
Treatment
Fit-up Blasting
Weld Painting
Welding Trials
Welding
Fit up Clamp
Contents
Erect Flares / Columns & Vessels
Cranes Heavy Lift Animation
Lift column from the horizontal and
rotate into the vertical
Erect Flares / Columns & Vessels - 3D Simulation
Gas Processing Facility
Flares / Columns / Vessels Erection
Tandem Lift to tilt flare
from horizontal to vertical
Tail
Crane
Trunnions
Main
Lift
Crane
Demag CC180-1 300 t crawler crane
72m boom & 42m luffing jib Path of Construction 59
Contents
Electricity Substation
Main Substation Horizontal Cross section
HVAC Room
Heat, Ventilation, & Air Conditioning Chillers
Local
UPS Equipment
Battery Room
Room Room
Transformer Bays
Structural Steel Building Single Storey
3D images to show Construction Sequence.
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
ⓒ David H Moloney
Steel Building Single Storey
Structural Steel
ⓒ David H Moloney
Structural Steel Building Multi Storey
3D images to show Construction Sequence.
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
ⓒ David H Moloney
Roof Covering
Structural Steel
ⓒ David H Moloney
Roof Covering
Structural Steel
ⓒ David H Moloney
Roof Covering
Structural Steel
ⓒ David H Moloney
Contents
Onshore Gas Pipeline Construction Sequence
Gas Processing Facility
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 Pause Slides to Read
Hydrotest & Pigging
Tie-in i.e. connect to existing pipeline
Miscellaneous
Overview Pipeline Construction Animation
To see animations, view YouTube film.
Cable laying 132KVa Electric
Cable Laying
Pipework
Brief Description
132 kVa Cable laying .
Cable Laying
Pipework
Cable Laying
Pipework
Cable Laying
Pipework
Contents
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.
Crossings – River, Motorway & Rail
Pipework
Horizontal Directional Drilling
Pipework
Overview Pipeline Crossings Construction Animation
Micro Tunnelling
Tunnels
Micro Tunnelling Sequence David H Moloney
Tunnels
ⓒ David H Moloney
Contents
Road Construction
Includes Sequence, Methods & Equipment
Road Construction Sequence Animation
Asphalt Pavement
Fencing & Gates
Includes Sequence, Methods & Equipment
Fencing
Sequence of Construction
Clear Scrub & Grade ground
Fix Corner & Strainer Posts
Fix Intermediate Posts
Fix Line Wire, Chain-link & Razer wire
Concrete ground beam
ⓒ David H Moloney
Miscellaneous
Fencing
Miscellaneous
Fencing
Miscellaneous
Fencing
Miscellaneous
Fencing
Contents
Setting out & Surveying
Setting out & Surveying
Contents
Emergency Phone Numbers & Response
Health, Safety & Environment
Dashboard is a single page, graphical representation of
HSE Monitoring & Reporting - Dashboard current HSE Issues and historical trends
Health, Safety & Environment
Health, Safety & Environment
Safety Precautions
Safety Training on Site
Miscellaneous
Diverting Existing Underground Utilities
ⓒ David H Moloney
Existing Underground Utilities & Overhead Cables - Safety Measures
Health, Safety & Environment
ⓒ David H Moloney
Health, Safety & Environment
Trench - Safety Measures
Trench - Safety Measures
Health, Safety & Environment
ⓒ David H Moloney
Site Safety Posters examples
Health, Safety & Environment
Air, Noise, Water & Soil Pollution
Environmentally Friendly Site
Health, Safety & Environment
Health, Safety & Environment
Water Pollution Prevention
Segregation of Waste
Health, 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
Contents
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.
Filing System
Contents
Dashboard is a single page, graphical representation of
Quality Assurance Dashboard current statistics and historical trends
Site Laboratory
General items
Contents
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
Programme using Timeline & 3D Images
POTABLE/FIRE WATER TANK
Pump House
Chiller Plant
Primary Substation-
IRRIGATION WATER TANKS
Irrigation Pump House-
Airport Central Utility Yard
Pump House
Piling
Chiller Plant-714
Pump House-
715
Primary Substation-711
Irrigation Pump House-
716
Chiller Plant-714
Pump House-
715
Primary Substation-711
Irrigation Pump House-
716
IRRIGATION WATER TANK
Chiller Plant-714
Pump House-
715
Primary Substation-711
Irrigation Pump House-
716
IRRIGATION WATER TANK
Chiller Plant-714
Pump House-
715
Primary Substation-711
Irrigation Pump House-
716
IRRIGATION WATER TANK
POTABLE/FIRE WATER TANK
Chiller Plant-714
Pump House-
715
Primary Substation-711
Irrigation Pump House-
716
IRRIGATION WATER TANK
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
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
Plant & Equipment List & Worker’s Job Titles
ⓒ David H Moloney
Contents
Temporary Contractors Site Facilities
Brief Description
Site Offices, Camp Accommodation for
1,250 workers, Canteen, Recreation,
Fabrication shops, Stores, Plant Yard. In five
locations along the route.
ⓒ David H Moloney
General Items Welfare Facilities
Toilets – Washing
Canteen, Drying Room, Toilet & Generator
ⓒ David H Moloney
General Items
Site Hoarding examples
ⓒ David H Moloney
General Items
Temporary Electricity Supply & Tower Lights
ⓒ David H Moloney
General Items
Wheel Wash Drive-through
ⓒ David H Moloney
General Items
Wheel Wash Drive-through
General Items
Weighbridge & Sheeting Access
ⓒ David H Moloney
General Items
Dust Suppression
ⓒ David H Moloney
General Items
Dewatering
Brief Description
Construction dewatering is the removal or
drainage of groundwater and or surface /
rain water usually by pumping to keep the
works dry.
ⓒ David H Moloney
General Items
Dewatering
ⓒ David H Moloney
Quarry & Aggregate Production
3D image to show Sequence, Method & Plant.
ⓒ David H Moloney
General Items
Quarry & Aggregate Production
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 Plant
Concrete
ⓒ David H Moloney
General Items
Concrete Batching Yard 3 Nr Mixers
Reinforcement Cutting & Bending Yard 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
ⓒ David H Moloney
Reinforcement Cutting & Bending
Concrete
ⓒ David H Moloney
Contents
Notes
Production by David H Moloney
My YouTube Channel link: [Link]
ⓒ David H Moloney
