Muhammad Ahmed Rana was assigned to work as a Piping Design Engineer for the Barzan Onshore EPC Project from May 5, 2012 to May 8, 2013. The presentation outlines included an overview of the Barzan project, operations of the spoolgen software used for automatic spooling and joint marking, the interface between spoolgen and the CMS construction management system, managing engineering and site revisions through change sheets, revising site spool drawings, and providing field engineering support.

1. Site Assignment
From 05-May-2012 to 08-May-2013
1
Barzan Onshore EPC Project
Muhammad Ahmed Rana
Piping Design Engineer
Descon Integrated Projects Pvt. Ltd.

2. Presentation Outlines
2
1. Barzan Project Overview
2. Spoolgen Operations
3. CMS and Spoolgen Interface
4. YS/FS Change Sheets
5. Site Drawing’s Revision Work
6. Field Engineering Support
7. Project Pictures

3. 3
1. BARZAN PROJECT
OVERVIEW

4. 1. Barzan Project Overview
4
 Total No. of Lines: 50,300
 Total Project Dia Inches: 3,600,000
 Total No. of Equipments: 1,100
 DESCON Scope
 No. of Lines: 10,600
 Total Dia Inches 690,000

5. Construction Subctractors
5
CCC NSH
DESCON QCON
JGC

6. Subcontractors Scope
6
Main Process Trains
• A100, Train 1
• A200, Train 2
Common Process and Main Utilities
• B100
• C100
Common Process and Offsite Utilities
• B200
• C200 & C300

7. Overall Plot Plan
7

8. Descon Scope Areas
8
 Sour Water Area
 MEG Regeneration
 Condensate Stabilization (Compressor Area)
 Flare K.O
 Effluent Treatment
 Inlet Facilities Area (Slug Catcher)
 Cooling Tower Area
 Flare
 Main Sea Water Line (42”-FRP)
 86” Cooling Water Line

9. 9
2. SPOOLGEN OPERATIONS

10. Organogram of Spoolgen and My
Responsibilities
10
DESCON
Planning&
FEDC

11. About Spoolgen
11
 Intergraph Software for Automatic Spooling and
Joint Marking
 Input File is IDF File generated from PDS or PCF
File generated from SP3D Software
 The outputs
 CAD Files (Spool drawings for Fabrication)
 Weld/Joint Information
 Material data for accurate material allocation
 Site Assembly/Bolting Information

12. 12

13. Advantages
13
Planning
and BOQ
Reduces
Manhour
Better
Material
Allocation
and Control

14. Spool Drawing Preparation and
Issuance
14
 Piping Isometric Review and Joint Marking
 Preparation of Input Data for Spoolgen Software
 Spoolgen Operations (FW Marking, Sheet Split)
 Output files Generation (CAD and Text data)
 CAD Drawing Along with Data issued to Subcon
 Maintaining Index and Issuance Control Sheets

15. Check list and Spoolgen Output
15
 Check List Used by JGC
 Joint Number Legends
 Sample Spool Drawing
 Sample Weld Info File
 Sample Material File
 Sample Assembly File

16. 16
3. CMS AND SPOOLGEN
INTERFACE

17. Construction Management System
17
 JGC In-house software for complete Construction
Management
CMS
Materal
Control
Test Pack
Control
FS Control
System
Welding
Control
Contruction
Planning

18. 18
3D (PDS etc.)
MACS
REQ
PCOM
ETRS / MTCS
SPOOLGEN
CMS
REQ
PO
Spool Piece wise
Material Data
(LOM)
Weld Joint Data
Assembly Data
PO/Shipping Data
(MSR Data)
E（3D） C（CMS）
Spool
Piece
Dwg
Spool
Dwg
P（PMS）
ISO wise
Material
Data(LOM)

19. 19
4. YS/FS CHANGE SHEETS

20. YS/FS CHANGE SHEETS
20
 Change Sheets Preparation for all Isometrics
(Engineering) Revisions
 Automatically generated from CMS
 Input for YS is “*.b” files
 Input for FS is Manually/Site Mark-up
 All spool drawings are updated as per the isometric
revisions
 Joint Additions, deletions, and cut and re-welds
 YS Revision Check List
 Sample YS sheet
 YS/FS Tracking Sheet
 Finally to DHT for Issuance to Subcon.

21. 21
5. Site Spool Drawings
Revisions Work

22. Site Revisions Work
22
 All Changes due to site work other than Engineering
Change
 Joint Change Request Form (JCRF)
 Shop Fabrication Errors
 Site Installation Errors
 Joint Category Change
 Change due to Construction Sequence (Hydrotesting)
 Cut and Re-weld due to RT Failure
 Joint added due to Random Pipe Length
 Change due to seam Weld orientation

23. Sample Site Revision Drawings
23
 Sample 1, Hydro Testing
 Sample 2, Change Due To Random Pipe Length

24. 24
6. Field Engineering Support

25. Plate Thickness for Hydrotesting
25
 Blind for Hydrotesting of 36” Line
 Mating Flange = 36” 600# ASME B16.47 Ser. B
 Material A36
 Design Pressure = 126.3 barg
 Blind Thickness as per ASME Sec VIII Comes out to
be 145MM

26. PAD Overlapping with Seam
26
 For 52” &56” lines, R.L received 9M instead of
plan 11M
 Drawings need to be revised as there were
additional joints

27. Calculation of Neck of PAD
27

28. Double PAD for AIV Lines
28

29. FTR (Field Trouble Record) Issuance
29
 FTR was issued by Subcon to JGC for any kind
of problem related to Fabrication/installation of
Piping
 Sample FTR

30. Field Trouble Isometrics-1
30

31. Field Trouble Isometrics-2
31

32. Field Trouble Isometrics-3
32

33. Field Trouble Isometrics-4
33

34. Spool dwg Hold and Release
34
 Spool Fabrication, Installation, Material Issuance,
and every thing got hold for YS Drawings
 So if there are many such drawings Shop cannot
proceed Fabrication
 Welders/Fabricators can sit idle in severe
conditions if there are too many revisions viz. not
acceptable in any case.
 Since all changes are not related to shop
fabrication, so shop can proceed fabrication for
such cases
 So, we provided information of spools that shop
can proceed fabrication without any impact by
revision

35. Spool dwg Hold and Release
35
 Spool Drawing With Impact on Fabrication
 Spool Drawing With No Impact on Fabrication

36. 36
7. Project Pictures (FOLDER)

37. 37
Thank you for Participation