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Document Development Guidance Department: Projects / Engineering Revision 1 – August 2018 Doc. No: AKH01-GUI-ENG-LST-001

Deliverables list for Projects in the fertilizer industry

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Contents

1. Synopsis .............................................................................................................................................. 2

2. Why develop specific guidelines and procedures ......................................................................... 3

3. Purpose of this document ................................................................................................................. 3

4. Project and Document Phases ......................................................................................................... 3

5. Deliverables of Identify Phase .......................................................................................................... 4

6. Deliverables for Select Phase .......................................................................................................... 4

7. Deliverables for Define Phase .......................................................................................................... 6

8. Deliverables for Execute Phase ..................................................................................................... 14

9. Deliverables for Operate Phase .................................................................................................... 23

10. Applicability ................................................................................................................................... 24

11. Responsibility ................................................................................................................................ 24

12. Develop your own organization procedures ............................................................................. 24

13. Definitions ...................................................................................................................................... 25

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1. SYNOPSIS

AmmoniaKnowHow.com and UreaKnowHow.com support fertilizer manufacturers by providing essential services to the industry, using our syngas technologies and scientific knowledge developed in multiple projects worldwide.

Together we initiate a program to enhance the guidelines and procedures for operation, engineering, maintenance and process safety in the fertilizer industry utilizing the best practices and standards available today.

Using knowledge gained from our industry, historic risk registers, lessons learned from projects and from FIORDA members we are committed to give proper advice to improve safety, reliability and projects performance of fertilizer plants.

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https://fiorda.eu/guidelines-list/

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2. WHY DEVELOP SPECIFIC GUIDELINES AND PROCEDURES

Guidelines and Procedures are developed to help staff and management teams run the organization. In the best use situations, procedures play a strategic role in an organization. They are developed in light of the mission and objectives of the company and they become the media by which management’s plans, rules, intents, and business and operation processes become documented and communicated to all staff.

Carefully drafted and standardized guidelines and procedures save the company countless hours of management time. Guidelines, procedures and employee handbook should be an important part of the operation. They should be the first thing given to a new employee (either in hard copy or an electronic version). They should also be easily accessible in their most up-to-date version. Hence it is extremely important that an organization’s procedures are a “living document” prepared and saved in Microsoft Word and easily exported into portable versions (like PDF) and made available over the company network.

3. PURPOSE OF THIS DOCUMENT Purpose of the Deliverables List for Projects is to define the basic level of documentation required for each phase of the project and to determine the level of responsibility for each engineering discipline during the review phase of each document.

Deliverables List for Projects document can be used as internal guideline by fertilizer manufactures providing contractors and consultants with clear requirements of deliverables for each project stage.

4. PROJECT AND DOCUMENT PHASES In general, a project is divided in 5 phases:

1. Identify 2. Select 3. Define 4. Execute 5. Operate

The number of documents, complexity and level of details increase for each phase while the project progresses. The status of deliverables changes and can be defined as following:

Preliminary Work on the deliverable has started; development is typically limited to sketches, rough outlines or similar levels of early completion;

Baseline A Baseline status refers to a level of maturity that is sufficient for a clear definition of the part of the engineering work covered by the document. This also comprises refinement of the Preliminary status as well as cross-functional reviews being conducted. Further Updated is required prior to Finalization / actual implementation.

Updated An Updated status refers to level of maturity, in which the Baseline document has been further developed and aligned cross-functionally. Final stage has not yet been reached. More than one updating cycle may be necessary.

AFD "Approved for Design": Engineering work has gone through appropriate steps of review and assurance, enabling the design to be frozen. Commencement of detail-design is the following step. Any significant modification of the Final document can only be achieved through formal "Management of Change" process (MoC)."

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Final A Final status refers to a level of maturity that is sufficient to proceed with implementation

of the engineering work. A deliverable having achieved a Final status shall not require change in the further course of the implementation. Any significant modification of the Final document can only be achieved through formal "Management of Change" process (MoC).

Applicable Document is issued for the specific project life cycle phase and does not require Update in next phases.

5. DELIVERABLES OF IDENTIFY PHASE During the Identify phase the disciplines involved in the project are in general the Project Management, Process and Mechanical. The status of documentation is Preliminary and Baseline and will include process basic functionality of plant, type of plant, basic function, basic interconnection to plant environment (technical, economic, environmental). Examples of deliverables to be developed in the Identify phase are:

- Milestone Plan - Risk Management Plan + Risk Register - Conceptual HAZID study - Time Schedule - Basis of Design - Condition Assessment Studies / Report - Pipeline (ISO-metrics) - general route profile - Block Flow Diagrams - Equipment List - Heat and Material Balances - Process Design Criteria Document - Process Flow Diagrams - Simulation Models, reports and listings - Tie in List - Fluid List - Authority Management Plan (Permits and Consents Strategy) - Site Identification Report - Stakeholder Register & engagement plan - Etc.

6. DELIVERABLES FOR SELECT PHASE The primary objective of the Selection phase is to demonstrate that the project will provide an acceptable level of risk and financial return as a sound investment for Client. The technical, commercial and financial aspects of the project will be assessed to select the optimal / preferred development and provide a robust case for progressing towards project realisation. In the Select phase more engineering disciplines are getting involved. Civil, Control & Instrumentation, Electrical, HSE, Cost Control will have their own deliverables together with Mechanical, Process and Project Management. Document status may vary, depending on discipline for example:

Discipline Deliverable Title Document status

Civil Geotechnical Report Preliminary

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Control & Instr. I/O List Preliminary

Control & Instr. Instrument Index Preliminary

Control & Instr. Control System Architecture Diagram Preliminary

Electrical Electrical Equipment List Preliminary

Electrical Electrical Key Single Line Diagram Preliminary

Electrical Electrical Load List Preliminary

General Eng. Design Philosophies for all Disciplines Preliminary

General Eng. General Arrangement Drawings Preliminary

HSSE Leak Detection Instrument Index Preliminary

HSSE Detailed HAZID study Preliminary

HSSE Coarse HAZOP study Preliminary

HSSE Hazard and effects register Preliminary

HSSE Design HSE case concept including ALARP demonstration Preliminary

HSSE Draft Emergency Response plan Preliminary

Mechanical Calculation Notes for Equipment Preliminary

Mechanical Corrosion and material selection philosophy Preliminary

Mechanical Mechanical Equipment drawings Preliminary

Process Piping & Instrumentation Diagrams Preliminary

Process Process Equipment and Systems Datasheets Preliminary

Process Process Equipment and Systems Specifications including Utility Preliminary

Process Operation and Control Philosophy Preliminary

Process Isolation Philosophy Preliminary

Process ESD and DCS Philosophy Preliminary

Project Management Compliance Register and regulatory action plan Preliminary

Civil Civil Works Specification(s) Baseline

Civil Technical Report Baseline

Civil Geotechnical Data Acquisition Plan Baseline

General Eng. Basis of Design Baseline

General Eng. Condition Assessment Studies/ Report Baseline

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General Eng. General Plant Layout (Plot Plan) Baseline

Mechanical Rotating Equipment Drive Selection Study Report Baseline

Process Equipment List Baseline

Process Fluids List Baseline

Process Heat and Material Balances Baseline

Process Process Flow Diagrams Baseline

Process Simulation Models, reports and listings Baseline

Project Management

Authority Management Plan (Permits and Consents Strategy) Baseline

Project Management Risk Management Plan + Risk Register Baseline

Process Block Flow Diagrams Updated

Process Tie in List Updated

Project Management Milestone Plan Updated

Project Management Project Reports Updated

Project Management Time Schedule Updated

General Eng. Basis of Design (non-process) Final

General Eng. Operation & Maintenance Philosophy Final

General Eng. Spare Parts Strategy Final

Process Process Design Criteria Documents Final

Project Management Scope of Work for Project Final

Project Services Cost Estimates Applicable

Project Management Risk Register Applicable

Others…

7. DELIVERABLES FOR DEFINE PHASE Define phase means the project work following the select phase and successful FEED Readiness Review and culminating in a FID submission documentation. In this phase, the requirements that are associated with the project result are specified as clearly as possible. This involves identifying the expectations that all the involved parties have with regard to the project result.

It is important to identify the requirements as early in the process as possible. Wijnen (2004) distinguishes several categories of project requirements:

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• Preconditions • Functional requirements • Operational requirements • Design limitations


Civil Architectural Drawings for Buildings Baseline

Civil Civil Works Specification(s) Final

Civil Technical Report Final

Civil Construction Drawings Baseline

Civil Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Baseline


Baseline


Baseline


Baseline


Final


Final

Control & Instr. I/O List Baseline

Control & Instr. Instrument Index Baseline

Control & Instr. Control System Architecture Diagram Baseline

Control & Instr. Process Control Narrative Baseline

Control & Instr. Cause & Effect Diagram Baseline

Control & Instr. Control System Specification Baseline

Control & Instr. Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Baseline

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Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline

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Baseline


Baseline

Electrical Electrical Equipment List Baseline

Electrical Electrical Key Single Line Diagram Final

Electrical Electrical Load List Baseline

Electrical Cable Routing/overhead line plans Baseline

Electrical Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Final


Baseline


Baseline


Baseline


Preliminary


Preliminary


Preliminary

Electrical Typical installation drawings Preliminary

Electrical Electrical cables List Baseline

Electrical Cathodic Protection System Specification Baseline


Baseline

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Baseline

Electrical (ATEX) Hazardous Areas: Risks assessment of explosions Preliminary

Electrical (ATEX) Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Baseline


Preliminary

General Eng. Condition Assessment Studies/ Report Updated

General Eng. General Arrangement Drawings Final

General Eng. Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Final


Final


Baseline

General Eng. Basis of Design Final

HSSE Identify major risks for C&C (joint SIMOPS and HAZID) Baseline

HSSE Construction HSSE readiness review Updated

HSSE Preliminary Bow-tie analyses Preliminary

HSSE Design HSE case including ALARP demonstration Updated

HSSE MAH Report Updated

HSSE HAZOP study Baseline

HSSE LOPA study Baseline

HSSE Design Safety Review Baseline

HSSE SIMOPS study Baseline

HSSE Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Baseline

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Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline


Baseline

Mechanical Calculation Notes for Equipment Baseline

Mechanical Corrosion and material selection philosophy Baseline

Mechanical Mechanical datasheets (process & utilities equipment, piping, valves) Baseline

Mechanical Mechanical General Arrangement Drawings Baseline

Mechanical Mechanical Specifications (process & utilities equipment, piping, valves) Baseline

Mechanical Pressure vessels drawings Preliminary

Mechanical Piping Calculations Baseline

Mechanical Piping Classes Specification Baseline

Mechanical Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Final

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Final


Preliminary


Preliminary


Preliminary


Preliminary


Preliminary

Process Vessels Sizing Final

Process Draining philosophy Baseline

Process Equipment List Final

Process Flaring and Blow Down Philosophy Final

Process Fluids List Final

Process Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Final


Final


Final


Final


Final

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Final


Final


Final


Final

Process Process Flow Diagrams Final

Process Draining Philosophy Final

Process Operation and Control Philosophy Final

Process Isolation Philosophy Final

Process ESD and DCS Philosophy Final

Process Commissioning & Start up Philosophy Final

Project Services Contingency Estimation Applicable

Project Services Cost Breakdown Structure Applicable


Project Services Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Applicable


Applicable


Updated


Applicable


Applicable

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Applicable


Applicable


Applicable

Project Management

Authority Management Plan (Permits and Consents Strategy) Final

Project Management Compliance Register and regulatory action plan Updated

Project Management Milestone Plan Final


Project Management Risk Management Plan + Risk Register Applicable


Project Management

Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Updated

Project Management

Entire list of Deliverables and Engineering RACI Matrix is available only for AmmoniaKnowHow.com & UreaKnowHow.com clients

Updated

8. DELIVERABLES FOR EXECUTE PHASE In this phase all documents shall be sufficient for the execution phase and checked by an appropriate certified body. Each deliverable shall have a high level of detail and fulfill the purpose for it is produced.


Civil Architectural Drawings for Buildings Final

Civil Construction Drawings Final

Civil Layouts Final

Civil BoQ's and MTO Final

Civil Calculation Report Final


Final

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Final


Final


Final


Final


Final


Final


Final


Final


Final

Control & Instr. Local Control System Specification Final

Control & Instr. Field Instruments Specification Final


Final


Final

Control & Instr. Control Room Specification Final

Control & Instr. Instrumentation Cables Specification Final

Control & Instr. Control Room Layout Drawings Final

Control & Instr. Cable Block Diagram Final

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Final


Final


Final


Final


Final


Final


Final

Control & Instr. Logic Diagrams Final

Control & Instr. Electrical/ Hydraulically/ Pneumatic Layouts for Instruments Final

Control & Instr. Panel, Cabinet and Desk Layout Drawings Final


Final


Final


Final


Final


Final

Electrical Operating philosophy for the power system Final

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Electrical Electrical equipment specifications Final


Final


Final


Applicable


Applicable


Final


Final


Applicable


Final


Applicable


Applicable


Applicable

Electrical Schedule of protective relaying settings Applicable

Electrical Material take off for all electrical equipment material Applicable

Electrical Cathodic Protection System Specification Final

Electrical Electrical Calculations (LV) Final

Electrical Electrical Block Diagrams Final

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Final


Final


Final

Electrical (ATEX) Hazardous Areas Drawing Final

Electrical (ATEX) Hazardous Areas: Equipment specifications Final

Electrical (ATEX) Hazardous Areas: Materials characteristics, including electrical resistivity Final

Electrical (ATEX) Hazardous Areas: Certificate EC Final

Electrical (ATEX) Hazardous Areas: Declaration of conformity EC Final

Electrical (ATEX) Manufacturer's Declaration for equipment which have not own source of ignition and are considered outside the scope of Directive 94/9/EC

Final

Electrical (ATEX) Documents for Ex equipment with conditions of use, e.g. for equipment with certificate numbers which have the suffix „X‘

Final


Final


Final


Final


Final


Final


Final


Final

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Final

Electrical (ATEX) Hazardous Areas: Report regarding initial inspection Final

Electrical (ATEX) Hazardous Areas: Information for Maintenance and repairs Final

Electrical (ATEX) Explosion Protection Document Final


Final

General Eng. Condition Assessment Studies / Report Final

General Eng. Operations Readiness Review Final

HSSE HAZID and HSSE risk assessment (for Construction & Commissioning) - joint SIMOPS and HAZID Final

HSSE Construction HSSE readiness review Final

HSSE Detailed Bow-tie analyses Final


Final


Final


Final


Final


Final

HSSE Fire and Explosion Analysis Final

HSSE Emergency System Survivability Analysis Final

HSSE SIL study/ classification Final

HSSE HSSE Management plan (for construction phase) Final

HSSE Independent verification of safety critical process control loops Final


Final

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Final


Final


Final


Final


Final


Final


Final


Final


Final

HSSE Leak Detection System Wiring Diagram Final

Mechanical Calculation Notes for Equipment Final

Mechanical Corrosion and material selection Philosophy Final

Mechanical Coating, painting and insulation specifications Final


Final


Final


Final

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Final


Final


Final


Final


Final


Final


Final

Mechanical Tie-in details Final

Mechanical Piping support schedule Final

Mechanical Piping support details Final

Mechanical Hydrostatic test diagram Final


Final


Final


Final


Final


Final

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Final

Mechanical Pressure vessels internal arrangement drawings Final

Mechanical Welding specifications and procedures Final

Mechanical Typical welding detail drawings Final


Final


Final


Final


Final


Final


Final


Final


Final


Final


Final


Final

Mechanical De-watering and drying specification Final

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Project Services Contingency Estimation Applicable

Project Services Cost Breakdown Structure Applicable


Project Services Progress Measurement System Applicable


Applicable


Applicable


Final


Applicable


Applicable


Applicable


Applicable

Project Services Work Breakdown Structure Applicable

Project Management Compliance Register and regulatory action plan Final


Project Management Risk Management Plan + Risk Register Applicable


Project Management Stakeholder Register & -engagement plan Updated

Project Management Time Schedule Updated

9. DELIVERABLES FOR OPERATE PHASE


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HSSE HSSE Management System Final

10. APPLICABILITY Deliverables List for Projects is a document owned by the Projects / Engineering department within the organization. They are responsible to assess the necessity of each deliverable depending on project complexity and scope of work.

11. RESPONSIBILITY A detailed RACI Matrix shall be developed for the following engineering disciplines:

- Process Engineering - Electrical Engineering - Control & Instrumentation Engineering - Civil Engineering - Static Equipment - Rotating Equipment - Piping, Valves & Pipeline Engineering - HSSE - Project Management - Project Services (Cost Estimating & engineering) - Project Services (Planning & scheduling)

Responsibilities can be defined as following: (R) Responsible The accountable person may delegate some of his/her tasks to the responsible

person, who then is in charge to achieve this task. The responsible person is the one who delivers the content of a document ("doer").

(A) Accountable The one who is ultimately in charge of completion of the deliverable or task -

there is only one accountable person per deliverable / task and this person approves this deliverable.

(C) Consulted Sought for their opinion, the consulted person bears expertise to share within the

creation process of the deliverable / task. (I) Informed Stakeholders to be directly informed are marked as such to be kept up-to-date

upon approval of the deliverable / completion of the task.

12. DEVELOP YOUR OWN ORGANIZATION PROCEDURES Although templates can give you a head start on procedures development, other factors must be considered as you write your own internal documents. One factor is your organization’s culture. Organizational attitudes toward procedures determine the spectrum. On one end of the scale are companies that have a procedure for everything. At the other end of the spectrum are companies that only have only a few guidelines (only those required by the laws that are relevant to that company). Most companies fall somewhere in between these two extremes. The manager writing any guideline needs to understand where on the spectrum the company it falls and how the policy can be made to fit the organization’s culture to enhance compliance.

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Other two factors to be consider when developing guidelines and procedures are the fertilizer technology that company employs and local and international standards applicable to the industry. Internal standards and procedures must be developed in line with these factors, being applicable for your own plants and in line with regulatory requirements. The last, but not least, factor when developing your own procedures is the best industry practice that you need to employ. Liaison with your fertilizer association, participation in industry meetings and conferences and using fertilizer industry consultants can bring a fresh eye, new ideas and enhance the quality of your own guidelines and procedures.

13. DEFINITIONS AFD Approved for Design

ALARP As Low As Reasonable Practicable

ATEX Atmospheres Explosible

BoQ Bill of Quantities

CCTV Closed Circuit TV

DCS Distributed Control System

ESD Emergency Shut Down

FEED Front End Engineering Design

FID Final Investment Decision

FIORDA Fertilizer Industry Operational Risks Database

HAZID Hazard Identification Study

HAZOP Hazard and Operability Study

HSE Health Safety Environmental

HSSE Health, Safety, Security and Environmental

HV High Voltage

LOPA Layer of Protection Analysis

LV Low Voltage

MAH Major Accident Hazards

MOC Management of Change

MTO Material Take Off

MV Medium Voltage

NDT Non-Destructive Test

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SIL Safety Integrity Level

SIMOPS Simultaneous Operational Studies

Disclaimer The information contained in this document is given in good faith and while every care has been taken in preparing these documents, UreaKnowHow.com and AmmoniaKnowHow.com make no representations and give no warranties of whatever nature in respect of these documents, including but not limited to the accuracy or completeness of any information, facts and/or opinions contained therein. Both companies, its subsidiaries, the directors, employees and agents cannot be held liable for the use of and reliance of the opinions, estimates, forecasts and findings in these documents.

Fertilizer Industrial Services Ltd

Venture House, Arlington Square Downshire Way, Bracknell, RG12 1WA, UK P: + 44 (0) 7494 783 534 Web: www.fertilizer.services E-mail: [email protected]

http://www.fertilizer.services/