CM-PE-400 General Procedure for The Production of Process Engineering Documents

Table of Contents

1. Purpose
2. General
3. Responsibilities
4. Procedure
5. Flowchart
6. References

1. Purpose

This Procedure covers the Production of Process Engineering Documents.

2. General

Process Engineering Documents as referred to in this Procedure are Equipment Process Data Sheets, Process Flow Diagrams/Heat and Material Balances, process studies and Engineering Flow Diagrams (EFD’s) with related documents.

This Procedure shall be read in conjunction with the Procedure for the Production of Engineering Documents (Ref. 6.2).

3. Responsibilities

The Lead Process Engineer assigned to the Project is responsible for the production, verification, approval and transmittal of process documents that are produced for the project.

The Process Engineer, Systems Engineer and Process Specialist (Process Control Engineer, Heat Exchanger Engineer, Environmental Engineer) assigned to the Project is responsible for the production of the Process Documents.

The Project Manager is responsible for obtaining client’s comments/approval on process documents when required by contract.

The Manager Process Engineering is responsible to review and approve stand alone process studies (performed by an individual engineer) or to assign a qualified independent engineer to perform the review/approval function.

4. Procedure

4.1 Preparation

Process Documents shall be prepared by Process Engineers, System Engineers and/or Process Specialists assigned to the Project. Normally after the Design Basis (Ref. 6.3) has been approved.

4.1.1 Process Data Sheets

In principle process design information regarding equipment shall, either manually or electronically (e.g. with EQDMS: EQuipment Data base Management System) be recorded on or in the format of the standard Process Data Sheet forms.

In the absence of such a standard Data Sheet form, a written document shall be produced on form, standard not defined here.

Process Data Sheet forms shall be issued using a cover sheet. This cover sheet bears the document number of the Data Sheet. The numbering system to be used is the same as for equipment specifications, as defined in the Work Instruction for The Numbering of Project Documents (Ref. 6.7).

The page numbering of Process Data Sheets is defined in Ref. 6.2.

4.1.2 Equipment List

Equipment summaries shall be compiled either manually or electronically (e.g. with EQDMS) in the format of the standard Equipment List forms.

The Equipment List shall be issued using a cover sheet, showing a Project Document number. The initial issue is due not later than the first issue of the corresponding Process Flow Diagrams. The responsibilities with respect to the initiation (by the Process Engineer) and updating (by the Systems Engineer) are within the Process Department. During the final phase of the Project the Equipment List becomes a Project Engineering Document. (see Ref. 6.2)

4.1.3 Process Flow Diagrams

4.1.2.1 Introduction

The Process Flow Diagrams (PFD’s) are the first Flow Diagrams developed during the engineering phase of a project. The purpose of the PFD’s is to:

a. establish the plant unit operations;

b. define the Heat and Material Balances;

c. provide a working tool for the Process Engineer;

d. provide a flow diagram on which the client can make comments and revisions before the detailed engineering commences;

e. provide a basis for the development of Equipment Lists and Plot and Site Plans;

f. provide an outline for the Systems Engineer to follow when developing the initial issue of the Engineering Flow Diagram (EFD).

When the PFD’s are certified, the EFD’s become the project working documents. After that the PFD’s require updating only for record purposes. A record of revisions to the PFD, such as a list of revisions, is not normally produced.

4.1.3.2 Types of Process Flow Diagrams

PFD’s are prepared for the chemical process, environmental, tankage and utility sections of the plant (i.e., all sections of the plant). In addition, special types of Material Balances, such as Steam Balances, are also considered to be PFD’s.

4.1.3.3 Preparation

The procedure for preparation of PFD’s is detailed below. A flowchart for PFD preparation is attached in 5.1. This depicts the procedure for a Company standard project.

The procedure for signing and approval of PFD’s will be in accordance with Ref. 6.2, and is also described in this section.

The Unit Process Engineer prepares (hand draws) PFD’s and transmits it to the Lead Process Engineer for his review.

The Lead Process Engineer reviews the PFD and transmits it to the Systems Engineering Coordinator for drafting.

The Systems Engineering Coordinator transmits the PFD’s to the 2D CAD facilities to be drafted.

The PFD drafting is back-checked by the Unit Process Engineer and initialed (under “By”). He then transmits it to the Lead Process Engineer.

The Lead Process Engineer signs the PFD (under “Ch’k’d”) (QC) and then transmits the document to the Engineering Manager for QA check (under “App’d”). After this check and approval cycle, the Lead Process Engineer transmits the PFD to the Project Engineering Aide for issue as “For Client Comments”.

4.1.3.4 PFD Review Meeting

In conjunction with this issue of the PFD’s, the Systems Engineering Coordinator establishes the time and place for the review meeting. As a minimum, Company personnel attending this meeting are the Lead Process Engineer, Unit Process Engineer, Instrument Engineer, Engineering Manager, as well as the client.

The PFD review meeting is held. Comments are discussed and then marked on reproducible copies of the PFD’s, as well as any revisions that have developed since the last issue of the PFD’s. Prints are transmitted to all meeting attendees immediately after the meeting. Minutes of meeting are prepared by the Unit Process Engineer and signed by the Lead Process Engineer and the Engineering Manager.

The Unit Process Engineer incorporates the comments onto the PFD originals (utilizing the 2D CAD facilities if required), initials them (under “By”), and transmits them to the Lead Process Engineer for his review.

4.1.3.5 Certified Issue

The Lead Process Engineer confirms that all comments are correctly added to the PFD’s, signs them (under “Ch’k’d”) (QC), and transmits them to the Engineering Manager. The Engineering Manager reviews them (under “App’d”) (QA), and then transmits them to the client for his signature, if required. Subsequently the signed PFD’s originals are transmitted to the Project Engineering Aide for issue as “Certified”.

Subsequent PFD issues will be made as required. As a minimum, they will be signed by the Lead Process Engineer (QC) and reviewed by the Engineering Manager (QA).

Heat and Material Balances are normally shown on Process Flow Diagrams. Alternatively they can be issued as a separate document.

4.1.4 Engineering Flow Diagrams

The procedure for preparing Engineering Flow Diagrams and related Documents is given in Ref. 6.6.

4.1.5 Process Studies

Small studies for clients are often undertaken by a single Process Engineer. The result is a study report document being issued to the client. Often studies do not have a strict design basis, but are a means of screening many alternatives. The basis of the study therefore should be established in the proposal document. Since these studies vary in scope and content, a standard document form or format is not available. The deliverables and table of contents will therefore be agreed upon beforehand with the client. Prior to issuing the study report, a technical review and approval will be performed in the Process Department by a Process Engineer assigned by the Manager Process Engineering. The cover sheet of the report will contain the issue number, date, description and signature blocks for initialing by the originator, the reviewer and for approval by the Manager Process Engineer or his delegate.

Process studies will be subject to review by an independent qualified member of the Process Department to ensure that the study meets the requirements. Preferably a draft copy is sent to the client for comments prior to final issue of this document.

Process studies often have no assigned Project Manager. In this case, the document will be issued to the appropriate Business Development Manager (unless otherwise directed) for transmittal to the client.

4.2 Checking and Approval

Process documents shall be reviewed and approved for adequacy by the Lead Process Engineer prior to issue. The review shall ensure that the data in the document to be issued meet the design input requirements as specified in the design basis (Ref. 6.3) and that the design data are adequate for a proper and safe functioning of the unit and/or equipment.

For authorization and signatory approvals of process documents see Ref. 6.2.

4.3 Issuing to Project

The originals of completed process documents can be issued to the Project Manager without the use of an Internal Document Transmittal (IDT). The use of such a transmittal is mandatory for documents, which do not have a document number (Ref. 6.5).

Instructions to Project and Specialists, which do not appear on the original document should be written on an accompanying memo or in case of the use of an IDT, on the transmittal in the “comments” space. A copy of this memo or the completed IDT shall be filed in the Process Department.

The document itself, the related memo (if used) and the IDT need to state the issue description and the issue date.

4.4 Clients Comments

The Project Manager approves the process documents and, if required by the Contract Department, submits a copy to the Client/Licenser for review/approval and returns the originals and one or two (heat exchange data sheet) copies of the documents to the Process Department. Originals of PFD’s and EFD’s, however, are kept by the Systems Engineering Group. Distribution of copies to other departments by the Process Department, other than via the Project Manager, is not allowed.

The issue block of a process document shall clearly indicate the status of the information on the concerning issue. For instance “for client’s comments/approval”.

Clients comments shall be handled as described in Ref. 6.4. The process document shall be updated by the originator and reissued, for instance as “client comments incorporated” or “released for mechanical design”.

4.5 Changes and Revisions

4.5.1 General

Each issue of a process document and the changes made on that document shall be identified as per Ref. 6.1.

Once a process document has been issued, any change to its contents will require a revised issue of that document.

Revisions of process documents shall be transmitted to the Project Manager by means of a new issue in the same manner as the first issue (see section 4.3). It is not allowed to do this verbally or per AVO.

The hard copy front sheet of process documents and/or the original data sheets shall be maintained and updated to contain the latest issue code, date and description so as to maintain all existing features.

4.5.2 Data Sheets

Mechanical design work shall normally not start without having a formal issue of the Process Data Sheet marked “released for mechanical design”. Approval from the Project Manager is required if, for special reasons, it maybe necessary to deviate from this rule.

Once a requisition has been prepared, updated process information is transmitted by marked up requisitions. The Process Data Sheet is not updated further unless this is contractually required.

The Specialist Engineers shall incorporate all process comments which are indicated by the Lead Process Engineer on the requisition into the next formal issue of the requisition.

Deviation from the information indicated on Process Data Sheets is not allowed without the agreement of the responsible Process Engineer and receipt of the changes indicated on the requisition covering the deviation.

In order to minimize revisions to the mechanical design of equipment, the Lead Process Engineer shall, prior to the issue of a Process Data Sheet “released for mechanical design” - ascertain that the process data are given correct at the time of the new issue.

When a hold on the issue of a Process Data Sheet, (until the process design data are complete) will affect the schedule, the Lead Process Engineer will consult the Project Manager and Lead Specialist Engineer to determine the best course of action.

The Lead Process Engineer shall advise the Project Manager immediately when process information already released as “certified for mechanical design” has to be revised. The Project Manager shall then decide, pending the nature of the changes, whether the design work is to be stopped or not.

4.6 Filing

All original process documents shall be filed by the originating Process Engineering group.

The Project Manager shall keep a separate file containing all issues of process documents released for his project.

5. Flowchart

5.1 Flowchart for PFD Preparation

Flowchart for Verification, Approval and Transmittal of Process Engineering Documents (except for PFD’s)

5.3 cont’d

6. References