Table of Contents
1. Design
General
This section covers the activities to ensure that the design output meets the design input requirements and that the design output has been developed against known acceptance criteria, conforms to appropriate regulatory and contractual requirements, and identifies the functional characteristics of the product that relate to safety and performance. In this respect the word "design" covers all process, project and specialist engineering and design activities.Planning
The planning of engineering activities for a project may be divided into the following phases, which could coincide:- the concept phase
- basic engineering
- detailed engineering and design
Activity Assignment
Qualified personnel equipped with adequate resources and facilities shall be assigned to the design and verification activities.
The quality of design shall be assured by experienced personnel.
The work shall be governed by Company procedures and standards and supported by the computerized facilities that may all be adapted or extended to satisfy the project requirements.
Company's comprehensive library contains reference books and journals together with the current copies of national and international codes and standards that shall be considered for the work.
The Departments maintain an index of technical/engineering computer programs.
Interfaces
For each project the administrative and technical interfaces shall be established and formalized to ensure a smooth flow of information and to ensure that all necessary specialists are involved in the appropriate activities.
Due consideration shall be given to:
- possible overlaps in the work of various disciplines
- possible split of work between various office locations;
- involvement of other disciplines to advise on technical and practical aspects.
Concept Phase
The concept phase, in Company, may start with the receipt of the enquiry from the client and with the preparation of the proposal.
The main purposes of this phase are:
- to define outline conditions and objectives.
- to work out a clear assignment of tasks
- to establish the basic planning and interfaces.
- establish/confirm the scope of services, deliveries and guarantee.
- establish/confirm criteria to be applied for optimizing the plant or sections of the plant.
- clarify client's requirements.
- establish/confirm the degree of reliability, availability and service life to be aimed for.
- draw up basic schedules and define essential milestones.
- define the Basic Design Data.
- establish raw materials/feed stocks and products for the plant.
- establish the required loadings and partial loadings.
- establish local conditions such as location, production facilities, environmental conditions, etc.
- clarify laws and official regulations to be observed, and permits to be obtained.
- select and establish the codes, norms/procedures and standards to be applied.
- define guidelines regulating the activities for the project. These describe the tests, reviews and approvals required by the client and or local authorities, the method of identifying and administering documents, the exchange of information, as well as the documentation of decisions and amendments.
- translate the assignment into construction regulations, design specifications and testing and inspection regulations. These documents are drawn up in the agreed form so that all those involved in the project are clearly and reliably informed.
Basic Engineering
The aim of the basic engineering phase may include:- define requirements for all plant components, taking into account all possible cases.
- define the installation concept and provide sufficient details of construction requirements.
- draw up flow diagrams.
- establish the material and heat balances.
- carrying out an upset operational condition analysis, resulting on the one hand in safety equipment, and on the other in design data (pressure, temperature) and additional safety requirements.
- simulate the various cases for the process chosen and confirm the types and number of pieces of equipment.
- determine the forces/stresses on individual pieces of equipment and/or their parts and select/define/design the equipment as appropriate and taking due account of optimum economics.
- selection of materials to be used for the individual components shall be based on the design data, corrosion, erosion and any special condition.
- prepare equipment and material specifications.
- draw any necessary installation plans considering feasibility, construction and safety requirements.
Detailed Engineering and Design
The object of the detailed engineering phase is to translate the information defined in the basic engineering phase into ordering specifications, drawings, calculations and parts lists to enable individual components to be procured, assembled and installed.
Detailed Engineering activities may include:
- drawing up the technical documents e.g.:
- specifications
- requisitions
- design drawings and calculations
- obtaining authorizations if necessary from the client and authorities.
- technical evaluation of bids.
- reviewing the manufacturer's documents and releasing for production.
- standardization of documentation for transferring information, i.e. form, content and distribution are defined.
- administration of documents to ensure that a general review of the number of documents produced and their status and distribution is available at all times.
- clearly regulated release procedures ensuring that the applicability of a document is obvious. This also applies to documents that cannot be in their final form because the planning is in stages. Here it is necessary to clearly identify those parts of the contents that are valid or to specifically describe the purpose of the information.
- limiting the number of revisions, to reduce adverse effects on quality. In case revisions are unavoidable, they should be followed through efficiently.
- localization of employees from the various departments in one area, as far as possible/necessary, with shared interfaces.
- regular coordination discussions under the chairmanship of the Project Manager.
- planned intermediate checks carried out in good time to ensure that all requirements are being met.
- checking and approving of technical documents required for manufacture and installation. This does not apply to subcontractors manufacturing documents.
2. Design Verification
General
Periodic review of drawings and models, along with rapid dissemination of information to all disciplines, assures that all are current with design development and progress.
Each discipline shall have established the necessary quality control, or checking procedures and standards for controlling the quality of their work. These activities shall be performed by individuals not directly responsible for the production of the documents being checked.
The group manager of each discipline shall conduct periodic independent reviews of the performance of personnel assigned to the task force through established review procedures.
Discipline Checks
Prior to an external issue, formal documents shall be independently checked by a person, within the specialist discipline, whose experience/qualifications are similar to or greater/higher than those of the originator in accordance with the procedure and standards.Inter-Discipline Checks
Inter-discipline checks shall be initiated for major documents in case the expertise of other specialists may contribute to the quality of the document.
These checks may be invited by either issuing a comment print routed through the disciplines or by issuing a separate comment print to each discipline.
Design Reviews
A design review is a formal meeting performed by a multi-discipline review team to examine aspects of the design, such as but not limited to:- safety
- environment
- constructability
- operability
- maintainability
- technical integrity
- contractual requirements
Design reviews can be held as e.g. a meeting or 3D model reviews.
Dependent on the nature and scope of a project, the types of design reviews may vary. They may range from reviews encompassing all technical documents and safety studies to reviews limited to certain key documents only, such as P&ID's, plot layouts and process design bases.
The client should be given the opportunity to attend any such review meetings.
All comments from such meetings shall be recorded either in a minutes of meeting or a signed and marked-up comment print of the reviewed document coupled to a list of attendees.
All comments/corrections from these reviews shall be incorporated in the document(s) prior to the checking and issuing formally for client's comments.
Project Quality Assurance
At the start of a project, the Manager of Quality Assurance, in coordination with all operational Department Managers, shall determine the schedule and extent of the checks and reviews required to be executed by the Department and Group Managers, independent of the task-force quality activities.
For these project audits the appropriate procedures and guides shall be used and the reports submitted accordingly. Audit checklists may be used to enhance a structured audit approach.
Design Validation
If Company acts as process licensor, process performance guarantees and the general test run procedure shall be defined and results of the tests recorded.
If information/correspondence is received from the client (after the plant has been started-up) that the plant satisfied all users' needs and/or requirements, that information will be filed by the Contracts Department. Technical information is kept in the Process Department files.
If contractually required, Company will perform any test runs.
3. Project Variation
General
For each project, procedures shall be established and implemented for the identification, documentation and appropriate review and approval of changes and modifications.Requirements
The following minimum requirements shall be covered by these procedures:- variations to the design input affecting the design output are to be reported to the Project Manager. Only variations that have been approved by the Project Manager shall be included in the design process.
- a requirement to change documents that have been "certified" for purchase, fabrication or construction shall be reported immediately to the Project Manager. Only after his approval shall the involved documents, that clearly reflect the approved changes, be re-issued.
- the Project Manager decides whether to inform the originator and any other party involved about potential variations and instruct whether or not work is to be stopped.
- upon rejection of a variation, the Project Manager shall inform the originator and any parties involved.
- records of agreed variation shall be maintained, as a minimum.
4. References
| Document Number | Title |
| CM-MA-121 | Control of Computer Programs Affected by Updates of Codes/Norms/Standards |
| CM-PE-002 | Preparation of EFD’s and Related Documents |
| CM-PE-101 | Identification and Verification of Project References |
| CM-PE-306 | Multi-Discipline Design Reviews |
| CM-PE-308 | Basic Design Data |
| CM-PE-313 | Control of Project Variations |
| CM-PE-404 | Engineering Data Transfer Between Process Department and Control Systems Department |
| CM-PE-500 | Preparation and Handling of Requisitions |
| CM-PE-505 | Design Models |
| CM-PE-506 | Model Review |
| CM-PE-801 | Constructability |
| BN-EP-012 | Preparation and Control of Engineering Calculations |
| BN-EP-013 | Establishing/Coding and Control of “Loans” of Department and Group References |
| BN-EP-304 | Work Division Between Control Systems and Electrical Groups |
| BN-EP-326 | Creation of CAD Plotplans, 3D PDS Piping Models, GA’s Isometrics and MTO |
| BN-PS-001 | Design Basis |
| BN-W-UE201 | Compliance with Local Applicable Laws and Regulations |
| BN-DG-UD001 | Checking of Flow Diagrams and Line Designation Tables |
| BN-DG-UD002 | Checking of Plotplans and Plant Layouts |