feed phase engineering design integrity(2)

FEED Phase

Engineering Design Integrity Workfl ow

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Introduction

FEED Engineering Design Integrity Workfl ow (EDIW)

EDIW is AMEC’s best practice guidance to Engineering Managers and supportingpersonnel for the delivery of technical integrity. It is an ‘aide-memoir’ that highlights the key deliverables and activities throughout the lifecycle of a typical FEED project.

FEED is broken into six phases:

1 Scope Defi nition and Engineering Execution Strategy

2 Commencement of FEED Design

3 Initial FEED Development and Hazard Identifi cation

4 Initial Design Review & Audit

5 FEED Design Approval (AFD)

6 Final Reviews and Feed Report Compilation

The workfl ow shown in the EDIW Road Map illustrates the execution sequence on a generic FEED Project. The vertical columns show activities that can be undertaken concurrently whilst the sequential fl ow of work is across the Road Map. As the deliverables and activities in each phase are completed, work can transition into the next phase.

Situations will arise when work will need to be be done out of sequence, typically to meet a demanding project schedule. Use of the EDIW allows the risks of out-of-sequence working to be identifi ed and the necessary mitigation strategies to be put in place.

AMEC’s corporate governance and assurance of Engineering will measure compliance with the EDIW workfl ow and ensure out-of-phase working is being identifi ed and managed. This document contains a copy of the FEED EDIW Road Map and includes detailed descriptions of the activities, the key engineering disciplines and supporting documentation.

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Phase 1Scope Defi nition and Engineering Execution Strategy

Preparation for commencement of detail design. To evaluate FEED deliverables to ensureengineering is suffi ciently mature for detail design to progress in a controlled and minimalchange environment. To confi rm Engineering Execution Plan.

Activities / Deliverables Description Supporting Documentation

1Engineering Execution Plan & Engineering Organisation Chart

Create Engineering Execution Plan complete with key supportingdocuments / information.

2Preparation/Validation ofConceptual Study Report/BoD

Confi rm maturity of Conceptual Design report. Identify any areas of concern and ensure these are captured on the Technical Risk Register.

3 Project Baseline StandardsEstablish which codes, standards and specifi cations are to be utilised, e.g.. Corporate, project, client, and confi rm procedure. Include inEngineering Execution Plan and/or Discipline Job Design Specifi cations.

Engineering Baseline Standards, Document No. OAG-X160-190-GDL-012 (previously AOD-92-043 )

4 Engineering Audit ScheduleCreate formal schedule to identify when technical integrity audits,design reviews, HAZIDS, HAZOPS, etc are to be carried out. Align to Level 3 Engineering Plan and include in Engineering Execution Plan.

Technical Safety Events Schedule(Lead Technical Safety Engineer)

5 Technical Risk Register Create formal Technical Risk Register identifying all possible risksassociated with the engineering design.

6 Integrated Engineering Systems

Agree engineering design tools to be used and confi rm that system hardware, software and support is available. Include issues such as PDMS or PDS, Cats and Specs, survey methods, dimensional control techniques, etc. Document and record in the Engineering Execution Plan and discipline job design specifi cations.

Engineering Systems Project Start-up Manual, Document No. OAG-X160-170-MAN-003

7 QRA & FRA Strategy

Establish status of project Quantitative Risk Assessment (QRA), Fire Risk Assessment (FRA) and Emergency Escape & Rescue Assessment (EERA) information and confi rm methodology for timely delivery intoengineering design process. Agree accountability for delivery, e.g..Client, 3rd party, AMEC, and record in Engineering Execution Plan.

Hazard Management Philosophy, OAG-X160-190-GDL-009 (previously AOD-97-001): Hazard & Risk Management, OAG-X160-190-PRO-024

8 Discipline Job Design Specifi cation

Defi ne the key project specifi c design parameters and operationalconstraints that are applicable to the appropriate discipline for the detailed design of the project. To identify key individuals , roles and responsibilities, design tools, key codes and standards, etc.

9 Level 3 Engineering PlanAgree work breakdown structure, develop CTRs and create level 3 integrated engineering plan covering all disciplines. To be included in Engineering Execution Plan.

10 Confi rm CE Compliance Strategy

Review and confi rm strategy for CE Compliance. Ensure discipline Lead Engineers are aware of their responsibilities and appropriate resources / measures are in place.

Corporate CE Compliance Strategy OAG-X160-190-MAN-001; Project Compliance with Pressure Equipment Regulations OAG-X160-050-PRO-001; Pressure EquipmentRegulations Guidelines AOD-97-047; ATEX Guidelines, OAG-X160-190-GDL-003; Machinery Directive Guidelines, O&G-ENG-REP-29-001; Electromatic Compatibility RegulationsGuidelines, OAG-X160-190-GDL-003; MC, TheElectrical Equipment (Safety) Regulations Guidelines, OAG-X160-190-GDL-003.

11 Prepare Interface Register Develop interface register to ensure all interfaces are identifi ed and managed.

The Electrical Equipment (Safety) Regulations Guidelines No: OAG-X160-070-GLD-002

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Phase 2Commencement of FEED Design

To formally kick off the Engineering Design Process in accordance with the project execution plan and to ensure that key engineering strategies / philosophies are in place.

Activities / Deliverables Description Supporting Documentation

1Safety Critical Systems/Elements and Performance Standards

Confi rm safety critical systems / elements and set appropriateperformance standards. i.e. functionality, reliability and survivability.

Hazard Management Philosophy, OAG-X160-190-GDL-009 (previously AOD-97-001); Hazard & Risk Management, OAG-X160-190-PRO-024; Design Verifi cation Activities (under DCR), OAG-X160-190-PRO-028; Platform Safety Case.

2 Document Distribution Matrix

Create formal document distribution matrix to ensure all disciplines & departments receive all necessary design information in a timely manner.

3 Structural IntegrityInterface

Ensure structural integrity interfaces are identifi ed & visible to Project, e.g. AMEC / Client focal points, Technical Authorities, Independent Verifi cation Bodies, etc.

4 Material Selection Report Report defi ning the requirements and specifi cations of necessarymaterial.

AMEC Corporate Material EngineeringSpecifi cations.

5 Hazard Management PlanCreate Hazard Management Plan identifying all key hazards, technical safety activities and the approach to managing Major Accident Hazards (MAH) in the design.

Hazard & Risk Management, OAG-X160-190-PRO-024; Management of Functional Safety Guideline OAG-X160-190-GDL-004

6 Piping Specifi cations Develop / confi rm baseline piping specifi cations, utilising AMECCorporate specifi cations where possible. AMEC Corporate Piping Specifi cations.

7 PDMS Catalogues Ensure PDMS catalogues are populated & available for all affected disciplines, utilising AMEC Corporate data, i.e. CPC, where possible.

8 CMSS Philosophy The purpose of this task is to defi ne and prepare the assuranceactivities to be undertaken aligned with the project categorisation.

Develop Control Monitoring and SafetySystems (CMSS) Philosophy covering keyinstrumentation and control systems e.g.Process Control System (PCS), Emergency Shutdown System (ESD) and Fire and Gas (F&G).

Phase 3Initial Design Development and Hazard Identifi cation

To develop initial design deliverables to Inter Discipline Review (IDC) stage and identifykey hazards.

Activities / Deliverables Description KeyDiscipline Supporting Documentation

1 HAZIDPerform hazard identifi cation studies, as identifi ed on Engineering Audit Schedule / Technical Safety Events Schedule.

Technical Safety

Project Hazard Identifi cation (HAZID)AOD-92-018; Engineering & Design Reviews,OAG-X160-190-PRO-013.

2 ENVIDFormal assessment of environmental aspects associated with a modifi cation or a change, and to proposeprevention or mitigating measures.

Technical Safety

Environmental Impact Identifi cation (ENVID) OAG-X160-190-PRO-121; Engineering & Design Reviews, OAG-X160-190-PRO-013.

3 PFD IDC Issue Process Flow Diagrams (PFD’s) on formalInter-Discipline Review (IDC). Process

4 Shutdown & Blowdown Philosophy

Explains the measures to shutdown safely and control blowdown and how this will be achieved. Process

5 P&ID’s IDC Issue Piping & Instrumentation Diagrams (P&ID’s) on formal Inter-Discipline Review (IDC). Process

6 Plot Plans / Layouts IDC Issue equipment Plot Plans / Layouts on formalinter-Discipline Review (IDC).

Piping and Layouts

7 HIPPS Review Initial review to establish requirements for a HighIntegrity Pressure Protection System. Instruments Management of Functional Safety,

OAG-X160-190-GDL-004

8 Dropped Object Study

Identify and assess the potential risks to drilling, production, process equipment, and manned areas from dropped or swinging objects. Where the consequence of a dropped object is considered signifi cant, to propose prevention or mitigating measures.

Technical Safety

9 Mechanical Handling Strategy

Develop Mechanical Handling Strategy including general approach / constraints, platform crane limits, installation philosophy, operation and maintenance, etc.

Mechanical and Structural

10 Particular MateriaAppraisals (PMA)

Where required, i.e. where Corporate PMA’s or EAM’s are not suitable, develop new PMA’s and obtain approval from Notifi ed Bodies (NoBo’s.

PED Focal Point

11 C&E IDC Issue Cause & Effects for formal Inter-Discipline Review (IDC).

Process and Instruments

12 Hazardous Area Layouts IDC

Issue Hazardous Area Layouts for formalInter-Discipline Review (IDC).

Technical Safety

13 Fire Risk Assessment (FRA)

Determines Fire & Explosion scenarios and identifi es requirements for prevention, control and mitigation measures.

Technical Safety

14 Blast Design Philosophy

Develop philosophy that assesses potential explosion hazards and identifi es appropriate blast loadings to be applied to the engineering design process, e.g.. Vessels, pipe supports, structural steel, etc.

Technical Safety

15 TR Impairment Study

Assessment of the vulnerability of a Temporary Refuge and demonstration of its capability to sustain life for a specifi ed duration when under attack by fi re, explosion and toxic gases.

Technical Safety

Fire Hazards Assessment, Blast Assessment, Dispersion Assessment, Emergency, Escape and Rescue Assessment, Heat StessAssessment

16 Equipment List & Data Sheets

Create master project equipment list identifying all major items of tagged equipment, e.g. vessels, pumps, motors, generators, hydrocycolnes, chemical injection packages, electrical switchgear, control panels, etc.

Mechanical

17Emergency Escape & Rescue Assessment (EERA)

To identify requirements for emergency escape & rescue, e.g. lifeboats, escape routes, plant layout, etc.

Technical Safety

18 PFP / AFP PhilosophyDevelop philosophy that identifi es requirements forPassive Fire Protection (PFP) and/or Active FireProtection (AFP).

Technical Safety

19 Power System Analysis Check power system capacities for increase power requirements for new equipment (Brownfi eld). Electrical

20 Preliminary Weight Report Prepare preliminary Weight report. Structural

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5

Phase 4Initial Design Review and Audit

To confi rm that the initial design development is robust.


1 Hazardous Area ReviewFormal Engineering discipline review of hazardous area layouts to confi rm requirements for the correct selection and location of equipment.

Technical Safety

Hazard and Risk Management ProcedureOAG-X160-190-PRO-024; Engineering &Design reviews, OAG-X160-190-PRO-013

2 P&ID Review Formal Engineering discipline review of P&ID's toconfi rm design basis.

Process,Piping,

Technical Safety,

Instruments

3 Plot Plans / Layout / 3-D Model Review

Formal Engineering review of Plot Plans / Layouts. The review shall ensure that the layout design complies with the required technical, safety, operability andmaintainability standards. Makes sure the layout is cost effective, ensures the constructability of the work and agrees the layout basis on which the detailed design can proceed.

Piping and Layouts,

Structural, Mechanical, Electrical, Technical

Safety, Process

Engineering & Design Reviews,OAG-X160-190-PRO-013

4 C&E ReviewFormal review of Cause & Effects diagrams to confi rm design basis and alignment with Hazard Management Plan.

Instruments, Process,Technical

Safety

Hazard and Risk Management ProcedureOAG-X160-190-PRO-024; Engineering & Design reviews, OAG-X160-190-PRO-013; Management of Functional Safety Guideline OAG-X160-190-GDL-004

5 Technical AuditObtain confi rmation, by sampling of project documentation, that the engineering of the project is to the required standard and free from errors.

Independent(Corporate

Engineering)

Technical Audit ProcedureOAG-X160-190-PRO-022

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Phase 5FEED Design Approval (AFD)

To ‘Freeze’ the Process design, and develop dependent design & procurement activities.


1 Final Design review Demonstartion that all of the design and review activities relevant to achieving design integrity have been performed.

Technical Safety Final Design Review - OAG-X160-190-PRO-013

2 PUWERAssessments

Conduct initial PUWER assessment typically by review of PDMS model and/or vendor / equipment supplier information received to date.

Technical Safety,

Mechanical


3 HAZOP

Hazard and Operability Studies, a systematic multi-discipline study based on the applications of guidewords to identify causes of potential hazards and operability constraints in a facility.

Process,Technical

Safety

Dependent on Project updated P&ID’s and C&E’s may be prepared from commented IDC’s from Phase 3 Formal HAZOP, OAG-X160-190-PRO-017 (previously AOD-92-022); Engineering & Design Reviews, OAG-X160-190-PRO-013 - Note: additional HAZOP’s may be required, i.e. earlier or later in the project. PEM to consult with Process & Technical Safety Lead Engineers.

4 BAT Report

The Final report which analyses the major environmentalissues that have been considered as part of the process toselect the fi nal option from the various alternativesconsidered. Thus preventing, or eliminating, or where the alternatives are not practicable, to then limit or reduceenvironmental impacts associated with the selected option.

Technical Safety

Procedure for Selection of Best AvailableTechniques (BAT) Procedure No:OAG-X160-190-PRO-030

5 Constructability Review

Conduct formal Constructability Reviews to ensure safe and effi cient installation of plant & equipment.

Affecteddisciplines +

Construction / Implementa-

tion Group


6 P&ID AFD Issue Approved For Design (AFD) Process andInstrumentation Diagrams. Process

7 C&E AFD Issue Approved For Design (AFD) Cause & Effects. Instruments

8 Process Data Sheets AFD Issue Approved For Design (AFD) Process Data Sheets. Process

9 HP / LP Interface Listing

Identify all HP / LP interfaces on formal register and ensure that all have been addressed satisfactorily via HAZOP’s and / or individual reviews.

Process

10 Holds Register Develop register to record & manage post AFD design holds. Engineering Manager

11 SIL Assessments

Conduct assessment to determine target Safety Integrity Level (SIL). Note: Where the target SIL is 3, then it is likely that a High Integrity Pressure Protection System (HIPPS) will be required. If the value is found to be 1 or 2, then a HIPPS will not be required.

Instruments Management of Functional Safety,OAG-X160-190-GDL-004

12 HIPPS Study

Conduct study to formally identify the performancerequirements of the High Integrity Pressure ProtectionSystem (HIPPS) and demonstrate that it is robust. Should include dynamic study for a range of transient conditions.

Process Management of Functional Safety,OAG-X160-190-GDL-005

13 Qualitative RiskAssessment (QRA)

Multi-disciplinary study of hazards, the likeihood of theiroccurrence and potential consequences in terms of harm to people and the environment.

Technical Safety

Fire Hazards Assessment, Blast Assessment, Dispersion Assessment, Emergency, Escape and Rescue Assessment, Heat StessAssessment

14 HIPPS Reliability Study

Conduct study to formally demonstrate that the High Integrity Pressure Protection System (HIPPS) complies with thereliability & availability criteria for the Project, e.g. asstipulated in the performance standards.

Instruments Management of Functional Safety,OAG-X160-190-GDL-004

15 Flow Assurance Conduct fl ow assurance studies to demonstrate the process design under a range of fl ow conditions, i.e. start-up to 100%. Process

16 EDAS Stage Gate Reviews

Demonstrate adherence to the EDAS Task Performance Crite-ria appropriate for Project Category.

Engineering Management

17 Technical Peer Review

Demonstrate adherence to the EDAS Task Performance Criteria appropriate for the Project Category and to ensure that engineering personnel are aware of EDASrequirements and adequately explain how those requirements are being fulfi lled.

Engineering Management

Phase 6Final Reviews and FEED Report Compilation

To ensure all fi nal design deliverables are completed and that client and statutory obligations are satisfactorily resolved.


1 FEED Report Collate all discipline inputs and fi nalise study report. ProjectManagement

All Discipline Reports and disciplinedrawings etc.

AMEC (LSE: AMEC) is a focused supplier of high-value consultancy, engineering and project management services to the world’s natural resources, nuclear, clean energy, water and environmen-

tal sectors. With annual revenues of over £2.5 billion, AMEC designs, delivers and maintains strategic and complex assets for its customers. The company employs some 22,000 people in around

40 countries worldwide.

For further information please see amec.com

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