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.
