Engineering and Design

Engineering and Design

Engineering Solutions to Meet the Most Complex Challenges

IEPC engineers are committed to developing engineering solutions to meet our Clients’ most complex requirements. Engineering disciplines include: civil, electrical, mechanical, piping and structural engineering; as well as advanced specialties such as simulation, enterprise integration, integrated automation processes and interactive 3D and 4D modeling. Many of our engineers are technical experts in their fields, presenting at conferences around the world.

IEPC collaborates with their client counterparts to develop integrated solutions that may include engineering, procurement, fabrication, construction (EPFC), maintenance and project management. From the earliest stages of project design, we involve the construction and commissioning teams to provide capital and schedule efficiencies.

Design Solutions Align with Client Objectives

IEPC’s primary goal is to execute a project that meets the Clients’ objectives for throughput capacity and quality of product. The detailed engineering and design phase is a key step delivering capital projects. We develop plans to ensure that the designs reflect Client requirements and facilitate construction of facilities meeting our Clients’ strategic objectives.

IEPC’s conceptual design capabilities align each project’s function, scope, cost and schedule with Client objectives to optimize project success. The conceptual design phase offers the best opportunity to assess business, commercial and technical risks; and to improve our Clients’ return on investment.

During conceptual design, we use our approach to deliver appropriate, cost-effective solutions, enhancing the value of Clients’ assets and increasing their long-term business success. This proprietary system begins with IEPC’s , a collaborative work practice that engages a project’s multidisciplinary team members during development.

The FOCUS process:

  • Assigns accountability for services and material
  • Builds early consensus across all disciplines and functional areas
  • Connects each project activity and decision to the estimate
  • Details EPFC in a conceptual design report
  • Establishes a detailed estimate
  • Reduces the number of change orders
  • Solves the project’s issues prior to execution

Other conceptual design services include feasibility studies, project-development planning, technology evaluation and recommendations, modular construction options, risk-management assessment, global siting, financing planning, constructability reviews, asset and life-cycle optimization and front-end engineering.

Design Reviews Focus on Client Project Requirements

Our Clients depend on IEPC for accurate and timely design reviews. We conduct design reviews at key project stages to ensure consistent, efficient focus on the Clients’ deliverables throughout the design process.

Design reviews for projects include:

Constructability, Maintainability and Operability (CMO) Reviews
CMO Reviews highlight, address and resolve issues early in the design process for an efficient design and construction process, minimizing overall project cost. Reviews focus on:

  • Constructability
    The reviews for constructability highlight any construction approach issues in the design to optimize the project’s quality, safety, capital cost and construction schedule. Maintainability and operability input is provided by the Client. Client expectations and requirements are established during the Client Alignment session.
  • Maintainability
    The review for maintainability addresses issues during a project’s design phase associated with completing expected maintenance tasks, including factoring reliability and maintenance considerations into the design basis, establishing processes ensuring minimal impacts associated with maintenance and prestart-up maintenance planning.
  • Operability
    This review, similar to maintainability, focuses on minimizing post-startup life-cycle costs of a plant and addresses plant operation, logistics and support issues during a project’s design phases.

Other design reviews for projects include:

Value Engineering Reviews
IEPC applies value engineering to projects at all levels of project execution. Value engineering reviews employ proven techniques at multiple design phases, with the primary objective of reducing cost without compromising project quality.

Plant Operations Safety Reviews (HAZOP Reviews)
HAZOP reviews ensure critical safety and operating characteristics are addressed for safe and proper functioning of the completed facility.

Inter-discipline Reviews (Squad Checks)
Internal reviews confirm necessary interfaces occur between the various engineering disciplines assigned to the project.

Model Reviews
Model reviews, conducted with the Client, verify the design accurately reflects the detailed definition of the project scope of work and design input requirements. They are held at approximately 30, 60 and 90 percent of design completion.

Reviews
These reviews ensure engineering and design are completed in accordance with the project baseline and estimate. The reviews are conducted throughout the design process, at approximately 25, 50 and 75 percent of design completion.

Technical / Peer Reviews
Technical / peer reviews may be conducted on critical items, or when the design is based on new technologies or products that have not been previously demonstrated as effective. The reviews are performed by individuals with knowledge of the area under review or by a qualified, independent organization.

Engineering Capabilities Meet Clients’ Expectations

IEPC’s engineers are some of the most experienced experts in their respective fields of expertise. They work every day to develop comprehensive, integrated solutions to meet Client objectives. Our teams are comprised of engineers who have worked on multiple projects in diverse industries.

Our engineering capabilities comprise proven processes and best practices available 24/7 via our award-winning knowledge-management system,. This system connects IEPC engineers and technical experts around the globe, providing a collaboration tool for solutions to complex project challenges. More importantly, IEPC executes all projects with paramount consideration for the health, safety and environmental well-being of all current and future project participants and stakeholders.

IEPC engineers are based in offices in 32 countries on six continents, providing support to Clients regardless of location. Our engineering offices provide design, engineering, fabrication, procurement and construction management support to other IEPC offices throughout the world for successful project execution.

Front-End Engineering & Design (FEED) Capabilities

Clients rely on IEPC to adequately define their project requirements before initiating a capital investment. Our front-end engineering and design (FEED) teams, using the experience gained from providing FEED services to Clients in diverse industries prepare documentation to support our Clients’ future investments. IEPC has provided FEED services for thousands of major projects, including first-of-a-kind technologies, world scale mega projects and licensor design packages. We have extensive experience preparing lump sum bid packages, as well as reference packages to facilitate completion of work in an expeditious timeframe.

Front-end engineering and design is the work required to produce quality process and engineering documentation of sufficient depth, defining the project requirements for detailed engineering, procurement, fabrication and construction of facilities and supporting a ±10 percent project cost estimate. This distinct project phase is typically used to:

  • Conduct hazardous operations reviews
  • Develop the engineering design packages that can be used to bid a lump sum EPC scope and / or provide the foundation for the detailed engineering phase
  • Evaluate options that will improve the return on assets (ROA)
  • Prepare cost estimates for scope definition and for project funding
  • Support internal funding requirements

Delivers Client Value for Process Plant Facilities during Front End Design
Optim Eyes  is a proprietary front-end engineering tool for plot optimization and preliminary layout, used to quickly evaluate design options for cost optimization of process plant facility designs.

Used on engineering studies, pre-FEED and FEED activities, OptimEyes enables the rapid creation of conceptual 3D plant models along with automated routing, equipment creation and material quantity downloads. IEPC’s multi-disciplinary design teams quickly create and evaluate multiple “what-if” scenarios, selecting and refining for the optimum facility arrangement.

IEPC EPC Projects Implement Construction-Driven Execution Approaches

IEPC’s engineering, procurement and construction (EPC) projects are construction driven. We confirm a smooth transition from process development and optimization-driven execution defined by the study phases, to a construction and start-up-driven execution platform defined by an EPC phase.

IEPC thinks first and foremost about executing project construction. Then we work backward, formulating how to get materials to the various sites. After this, IEPC determines how and where to drive engineering. Key elements of IEPC’s construction-driven execution approach are as follows:

  • Best practices implementation through all aspects of HSE, labor, material management, construction and construction technologies
  • Best-in-class systems and technology to improve productivity and provide accurate progress assessment and forecasting
  • Design/procurement sequencing to support construction
  • IEPC’s global Construction Operations support group for personnel, training, tools and procedures
  • Integration of construction methodologies and execution throughout the project’s life cycle
  • Maximizing preassembly/modules on and off site where applicable
  • Proactive, early construction plans and constructability reviews

More specifically, IEPC verifies handover sequencing and construction input are incorporated during front-end loading (FEL). Our experts lead the FEL process to define and coordinate scopes aligned with a construction and supplier strategy, allowing for maximum schedule enhancement. Key elements of this construction-driven approach include the following:

  • Definition and monitoring of construction work packages
  • Delivery of engineering and procurement services aligned with construction work packages
  • Development of engineering, procurement, fabrication and construction schedules reflecting the start-up and handover sequence and completion dates
  • Early identification of the commissioning systems and, as a consequence, the handover systems
  • Front-end development by the construction team of site logistics, craft resource capacity and the sequencing of construction activities by work breakdown structure

Value Engineering for Cost Savings

Value Engineering is a formal, structured process to ensure capital projects meet or exceed cost objectives without compromising project quality. IEPC’s project teams use value engineering throughout a project, evaluating options with a focus on reducing project capital costs as well as life cycle costs.

The value engineering process divides the total project’s scope of work into components, examining each individual component for alternatives that offer benefits in the areas of engineering design, equipment and material selection, construction and operations and maintenance. It is a structured application of proven techniques, applied at multiple phases of the project, with the primary objective to identify cost reductions.

Value engineering is an area in which we excel, with an established record of success in achieving major cost benefits for our Clients.