Process Plant Engineering Activity Model Safety & Environment Case
MANAGEMENT ACTIVITIES SET ENGINEERING POLICY & STANDARDS
PRODUCE & MAINTAIN FEASIBILITY & FINANCIAL CASE
CONTROL OPERATIONS & ENGINEERING ACTIVITIES
OBTAIN AGREEMENT WITH REGULATORY BODIES
REGULATORY BODIES
Regulatory Requirements Authorisations
Process Definition - Process Stream Properties & Composition - Required Unit Operations - Process Flow Diagrams - Energy Balance Control Philosophy Costs, Benefits & Timings Safety / Regulatory Requirements
PRODUCE DETAILED PROCESS DESIGN
PRODUCE CONCEPTUAL PROCESS DESIGN Define Overall Requirement
Identify Candidate Processes
Identify Safety/ Regulatory Requirements
Provide Input to Feasibility / Financial Case
Design Process
Define End Requirements
Performance requirements Operating Procedures Operating Conditions Alarm / Trip Settings Safety & Environment Case
Produce Functional Specification for Equipment
Produce Piping & Instrumentation Diagrams
Define Unit Operations Produce Energy / Mass Balance
Identify Start Conditions - Define battery Limits - Identify State of Plant to be Modified
COMMISSION PROCESS & HANDOVER PLANT
Produce Control Requirements Specification
Produce Composition of Process Streams
Identify Control Requirements
Define Relief & Blowdown Philosophy
Identify Trip Requirements
Define Protective System (Including Fire) Philosophy
Produce Control Requirements Specification
Define Control Philosophy
Produce Plant Operating Procedures
Satisfy Safety Requirements
Produce Commissioning Plan
Train Commissioning Personnel
OPERATE PLANT Perform Acceptance Testing
Commission Plant
Perform Trip Tests Perform Cold Commissioning Perform Hot Commissioning
Define Hazardous Areas
Produce Process Flow Diagrams
Plant status Ground Drains Status Safety Case As Built & As Modified Drawings
As-Built Drawings Operating Procedures Acceptance Test Results Handover Certificate
Ensure Safe Plant Operation
DECOMMISSION PLANT
Plan & Schedule Plant Operation
Identify Plant Performance Envelope
Update Operating Procedures
Obtain Operating Procedures
Compare Performance to Specification
Finalise Agreement with Regulatory Bodies
Obtain Operating Schematics
Plan Plant Operations
Define Safety and Security Procedures
Schedule Plant Operations
Identify Corrective Actions & Responsibility
Tune Control Systems
Handover Plant for Operation
Perform Plant Handover
Define Operating Modes
Obtain Certificate to Operate
Produce Safety & Environment Case
Preliminary Engineering Design - Equipment Lists - Preliminary Equipment Specifications - Utility Requirements - Preliminary Layout Drawings - Weight & Volume Estimates - Control Systems Architecture - Technical risks Assessment Engineering Philosophies - Design Philosophies - Construction Philosophies - Commissioning Philosophies - Operations Philosophies - Safety Philosophies - Containment Philosophies Availability Requirements Cost & Time Estimates Safety & Regulatory Requirements Codes & Standards
Process Stream Data Process Flow Diagrams Costs, Benefits & Timings
PRODUCE CONCEPTUAL ENGINEERING DESIGN Determine Engineering Approach
Produce Conceptual Mechanical Engineering Design
Produce Major Equipment Design Philosophy
Produce Major Equipment Design Philosophy
Identify Regulatory Requirements
Produce Preliminary Equipment Specifications
Produce Preliminary Equipment Specifications
Produce Cost & Time Estimates
Produce Cost & Time Estimates
Produce Control System Architecture
Produce Preliminary Weight & Volume Estimates
Produce Preliminary Weight & Volume Estimates
Produce Cost & Time Estimates
Determine Status of Existing Plant
Produce Major Equipment Design Philosophy Produce Preliminary Equipment & Line Specifications
Define Mechanical Commissioning Philosophy
Identify Materials of Construction
Define Electrical Commissioning Philosophy
Define Containment Philosophy Produce Technical Risks Assessment
Produce Conceptual Civil/Structural Engineering Design
Define Preliminary Plant Layouts
Produce Detailed Mechanical Engineering Design
Produce Detailed Electrical Engineering Design
Produce Detailed Control & Instrumentation Engineering Design
Produce Building & Plant Services Design
Produce Detailed Civil / Structural Engineering Design
Review Site Alternatives & Conditions
Produce Site Survey / Soil Investigation
Produce Piping & Mechanical Equipment Design
Review & Detail Plant / Building Electrical Requirements
Review & Detail Instrumentation Plant / Building Requirements
Produce Site Layout Produce 3D Model
Produce Domestic Water, Sewerage & Storm Water Design
Produce Preliminary Layout Drawings
Define Civil / Structural Philosophies
Produce Equipment Handling Systems Design
Produce Earthing Requirements (Static, Lightning, Power)
Produce Clean Earthing Requirements
Coordinate Interfaces Between Design Areas
Produce Environmental Control Systems Design
Identify Materials of Construction
Produce Detailed Mechanical Equipment Specifications
Produce Communication System Design
Produce Measurement Instrumentation Specification
Produce Site Construction & Installation Methodology
Produce Lighting & Small Power Design
Produce Electrical Cable Runs Design
Produce Actuator Specifications Produce Control Systems Specifications
Define Test & PreCommissioning Requirements
Produce Power Distribution Systems Design
Produce Studies for Cranage & Handling Microstation
Produce Preliminary Weight & Volume Estimates Define Control & Instrumentation Commissioning Philosophy
Produce Preliminary Building or Module Layout Drawings Produce Cost & Time Estimates Produce Preliminary Weight & Volume Estimates
Define Mechanical Equipment Spares Requirements Produce Mechanical Maintenance Procedures
Define Construction Philosophy
Produce Electrical Environment Control Requirements Define Electrical Equipment Spares Requirements
Define Building / Structural Commissioning Philosophy
Define Signal Transmission Pathways Produce Environment Control Requirements for Instrumentation
Produce Detailed Safety Engineering Assessment
Produce Construction Plans
Establish Construction Services
Produce Contract Plan Produce Construction Plan
Produce Room / Module Specifications
Erect Plant
Perform Civil/Structural Construction
Perform Conformance Checks
Erect Major Plant Items
Produce As-Built Specifications & Drawings
Construct Piping
Produce Civil Construction Drawings
Install Electrical & Instrumentation Systems
Design Containment Systems
Pre-Commission
Identify Unfinished Work
Complete Special Finishes, Thermal Insulation & Painting
Equipment & Materials Catalogues - Equipment & Materials Specifications - Equipment & Material Availability & Prices - Spares Lists Delivery dates Vendor Drawings Certification Equipment procedures - Installation Procedures - Commissioning Procedures - Operating Procedures - Maintenance Procedures Invoices
Maintain List of Preferred Suppliers Maintain Relationship with Suppliers
Equipment & Materials Requirements & Specifications Required on Site Dates Inspection Results Shipping Details Payment Details
Issue Enquiries
Handover to Process Commissioning
Ensure Safe Working Conditions
Finalise Regulatory Approvals
Inspection Requirements Work Permit Requests Notification of Work Completion
State of Equipment Value of Equipment Equipment Records
Define Maintenance Approach
Clean Plant for Testing and Commissioning
Obtain Plant Availability Requirements
Prepare Equipment for Commissioning
Obtain Equipment Records
Perform PreCommissioning Tests
Obtain Plant & Equipment Drawings
Perform Baseline Inspection
Obtain & Develop Maintenance Procedures
Plan Actual Maintenance or Inspection
Respond to Maintenance Request Identify Routine Maintenance Requirement Identify Inspection Requirements
DEMOLISH PLANT AND RESTORE SITE Prepare for Maintenance or Inspection
Maintain or Inspect Equipment
Obtain Equipment Records Obtain Plant & Equipment Drawings Obtain Maintenance Procedures Obtain Resources
Obtain Equipment Records
Obtain Work Permits
Obtain Plant & Equipment Drawings
Obtain Inspection Reports
Obtain & Develop Spares Strategy
Obtain Maintenance Procedures
Produce Painting & Surface Finish Specifications
Obtain Hazardous Materials Data
Obtain Plant Availability Requirements
Produce Weight Schedules
Train Maintenance & Inspection Staff
Design Foundation Structures
Evaluate Bids
Compile Bidders List
Condition Bids
Produce Enquiry Documents
Select Supplier
Compile Conditions of Contract
Mothball Plant
Determine Inspection Requirements
Accept Engineering Work
Prepare Site for Work Perform Maintenance or Inspection Record Resources Consumed Update Equipment Records
Define Demolition Plan Demolition & & Restoration Restoration Requirement
Define Demolition Requirements
Produce Demolition Procedures
Define Restoration Requirements
Produce Resource Estimates
Perform Safety & Environment Study
Produce Demolition & Restoration Plan
Prepare for Plant Demolition
Demolish & Secure Plant
Obtain Equipment Records Obtain Plant & Equipment Drawings Obtain Maintenance Procedures Obtain Resources
Dispose of Site
Restore Site
Prepare Site
Survey Site Contamination
Archive Records
Dispose of Plant
Remove / Treat Contaminated Material
Finalise Regulatory Approval
Box up & Secure Plant to Remain
Dispose of Contaminated Material
Remove Plant
Restore Environment
Obtain Work Permits Obtain Inspection Reports
Identify Resource Requirements Schedule Maintenance & Inspection
Materials & Equipment Requirements & Specifications Required On Site Dates
Equipment & Materials Catalogues - Equipment & Materials Specifications - Equipment & Material Availability & Prices - Spares Lists Delivery dates Vendor Drawings Certification Equipment procedures - Installation Procedures - Commissioning Procedures - Operating Procedures - Maintenance Procedures Inspection Results Shipping Details
Disposal Records Restoration Records Handover Records Final Regulatory Approvals
Copyright Notice
Maintain Suppliers List
Clean Plant
Archive Plant Records
Dispose of Inventory
PROCURE & CONTROL
SUPPLIERS & FABRICATORS
Provide Temporary Services
Approve Work Permits
Shutdown & Clean Out Plant
Define Preventative, Breakdown, Shutdown Maintenance Strategy
Design Process Effluent Drainage Systems
Equipment & Materials Catalogues - Equipment & Materials Specifications - Equipment & Material Availability & Prices - Spares Lists Delivery dates Vendor Drawings Certification Equipment procedures - Installation Procedures - Commissioning Procedures - Operating Procedures - Maintenance Procedures
Equipment & Materials Requirements & Specifications Required on Site Dates
Define Final Status
Provide Decommissioning Equipment
MAINTAIN EQUIPMENT Produce As Built Surveys
Clean & Mothball Plant
Isolate Services
Plant Status Plant Records Inspection Requirements Regulatory Approvals
Produce Bill of Quantities
Produce Electrical Maintenance Procedures
Perform Preparatory Works
Request Engineering Work
Optimise Plant Performance
As-Built Drawings As-Built Equipment Specifications Spares Lists Installation Procedures Maintenance Procedures Inspection results Unfinished Work Details
Produce Site Survey / Soil Investigation
Produce Fire Protection Systems Design
Start-up Plant
Produce Decommissioning & Restoration Plan
Identify Current Status
As-Built Drawings Equipment Commissioning Procedures Equipment Operating Procedures Inspection & Testing Records Handover Certificate
CONSTRUCT & PRE-COMMISSION PLANT
Produce Detailed Layout & Construction Design
Identify Requirement for Engineering Work
Monitor Plant Performance
Engineering Work Requests Working Conditions Requirements Engineering Work Permits Acceptance of Engineering Work
Detailed Engineering Design - Detailed Equipment Specifications - Piping & Instrumentation Diagrams - 2D Schematics - 3D Model - Construction Drawings Equipment Procedures - Installation Procedures - Commissioning Procedures - Operating Procedures - Maintenance Procedures Vendor Drawings Spares Lists
PRODUCE DETAILED ENGINEERING DESIGN Produce Conceptual Safety Engineering Design
Define Safety Philosophies
Identify Materials of Construction
Obtain Codes & Standards
Produce Conceptual Control & Instrumentation Engineering Design Identify Materials of Construction
Review Process Design
Define Engineering Design Strategy
Produce Conceptual Electrical Engineering Design
Detailed Process Design - Piping & Instrumentation Diagrams - Functional Specifications - Control Specification - Alarm / Trip Settings - Utility Systems Requirements - Design Philosophies Availability Requirements Safety Systems Specification Operating Procedures Codes & Standards
Configure Plant
Account for Plant Performance
Maintain Safety Case Train Operating Personnel
Define Commissioning Requirements
Request and Approve Work on Plant
Operation of Plant
Commit Purchase
Produce Purchase Orders Confirm Final Conditions of Contract
Expedite Manufacture
Expedite Progress Authorise Stage Payments Respond to Technical Queries
Inspect
Inspect Equipment, Materials & Services Respond to Concession Requests
Release for Shipment From Supplier
Ship Goods From Supplier
Issue Release Note
Pack Goods
Close Out Purchase Order
Make Shipping Arrangements
Authorise Final Payments
Ship Goods
Control & Issue Equipment & Materials
Produce material Stock & Strategy Unload Goods Store Goods Control & Monitor Stock Issue & Transport Goods to Required Location
coloured wall chart (this document) and a Microsoft VISUAL BASIC program. Copies may be obtained from the STEP Consortium at:
The copyright of the contents of this document is assigned to the Process Industries STEP consortium and its successors. However the contents may be freely distributed or copied, in full or part, provided due acknowledgement is made.
The following organizations provided the information that was used to generate the model and reviewed the model at various stages of its production. AMEC Engineering Ltd AKZO Engineering bv British Nuclear Fuels plc Shell International Harrow Associates ICI Engineering Ltd Nuclear Electric plc SINTEF
QMS, Beech House, 1 Yorktown Road, Sandhurst, Camberley, Surrey GU17 8DX, United Kingdom Contact: WR Mesley Telephone: 01252 878482 (Outside UK: +44 1252 878482) Facsimile: 01252 877386 (Outside UK: +44 1252 877386)
Acknowledgements
Lloyd's Register of Shipping Ingevision Framatome d'Information National Institute of Standards & Technology Process Industries STEP Consortium (PISTEP) Eutech Engineering Solutions Ltd John Brown Engineers & Construction Ltd The British Petroleum Company plc University of Newcastle upon Tyne
Introduction This model and its associated documentation has been produced as an aid to those involved in the production of Application Protocols for the Process Industries in the STEP (ISO 10303) standard. It provides an overview of the main activities and data flows associated with the life cycle of process plant. It is emphasised that the aim of the model is not completeness but communication to those go require to understand the main interaction between the major phases of engineering activities in the process plant life cycle. With this aim only the major data flows are shown and minor data flows and feeds back to earlier phases of the life cycle have been ignored. The activities are depicted as serial streams for the process and engineering activities. However, the activities may be ignored, combined or performed concurrently dependent upon the requirements of the task to be undertaken. This model will be made available in five forms, a paper document (A4), an electronic version of this document in Microsoft Word for Windows' version 3.0 or 6.0, a Microsoft Powerpoint file suitable for version 3.0 or 4.0, a
Purpose To identify the activities which create and use engineering data that we wish to share and exchange in the Process Industries. Something that engineers in the Process Industries will readily understand and identify with. Viewpoint A Plant Operators view based upon the Facility and Equipment life cycle. Context Statement This activity model provides a simplified view of the Process Plant Life Cycle activities and indicates areas of interest and data flows that may be modelled in a more formal manner. As such, this model should prove useful in planning and developing Application Protocols to meet the needs of the Process Industries within the ISO 10303 (STEP) environment. Exclusions and Inclusions The model excludes: 1. Design and manufacture of standard parts. e.g. Pumps, valves etc. 2. Development, Marketing and Transportation (other than pipelines) of manufactured product. 3. General Management activities. 4. The management of human resources and the supply of computing services. 5. Minor data flows.e.g. Minor Feedback's etc. The model includes 1. Engineering Management activities. 2. Authorisations and Permissions both internal and external.e.g. License to Operate.
