This workflow is a good practice guidance to Engineering Managers and supporting personnel for the delivery of technical integrity. It is an ‘aide-memoir’ that highlights the key deliverables and activities throughout the lifecycle of a typical Detailed Design project.
Detailed Design is broken into seven phases:
Phase 1： Scope Definition and Engineering Execution Strategy
Phase 2： Commencement of Detailed Design
Phase 3： Initial Design Development and Hazard Identification
Phase 4： Initial Design Review & Audit
Phase 5： Approval for Design (AFD)
Phase 6： Approval for Construction (AFC)
Phase 7： Design Close-Out
The workflow shown in the follow Road Map illustrates the execution sequence on a generic Detail Design Project. The vertical columns show activities that can be undertaken concurrently whilst the sequential flow 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 workflow allows the risks of out-of-sequence working to be identified and the necessary mitigation strategies to be put in place.
HBP’s corporate governance and assurance of Engineering will measure compliance with the workflow and ensure out-of-phase working is being identified and managed. This document contains a copy of the Detail Design Workflow Road Map and includes detailed descriptions of the activities, the key engineering disciplines and supporting documentation. Phase 1: Scope Definition and Engineering Execution Strategy
Preparation for commencement of detail design. To evaluate FEED deliverables to ensure engineering is sufficiently mature for detail design to progress in a controlled and minimal change environment. To confirm Engineering Execution Plan.
Activities / Deliverables
Description
Key Discipline
Supporting Documentation
1
Engineering Execution Strategy
Review / confirm Engineering Execution Strategy, e.g. execution locations, workshare, disciplines required, specialist support, etc.
Project Manager and Project Engineering Manager
Tender documentation, Project Execution Plan (PEP)
2
Feed / BoD Validation
Confirm maturity of Front End Engineering Design. Identify any areas of concern and ensure these are captured on the Technical Risk Register.
Project Engineering Manager
3
Project Baseline Standards
Establish which codes, standards and specifications are to be utilised, eg. Corporate, project, client, and confirm procedure. Include in Engineering Execution Plan and / or Discipline Job Design Specifications.
Create 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.
Engineering Execution Plan & Engineering Organisation Chart
Create Engineering Execution Plan complete with key supporting documents / information.
Project Engineering Manager
6
Integrated Engineering Systems
Agree engineering design tools to be used and confirm 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 specifications.
Engineering Systems and All Disciplines
Engineering Systems Project Start-up Manual, Document No. (DOCUMENT CODE)
7
QRA & FRA Strategy
Establish status of project Quantitative Risk Assessment (QRA), Fire Risk Assessment (FRA) and Emergency Escape & Rescue Assessment (EERA) information and confirm methadology for timely delivery into engineering design process. Agree accountability for delivery, eg. Client, 3rd party, HBP, and record in Engineering Execution Plan.
Define the key project specific design parameters and operational constraints 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.
All Disciplines
9
Level 3 Engineering Plan
Agree work breakdown structure, develop CTRs and create level 3 integrated engineering plan covering all disciplines. To be included in Engineering Execution Plan.
All Disciplines
10
Confirm CE Compliance Strategy
Review and confirm strategy for CE Compliance . Ensure discipline Lead Engineers are aware of their responsibilities and appropriate resources / measures are in place.
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
Key Discipline
Supporting Documentation
1
Performance Standards & Verification Scheme
Confirm safety critical systems / elements and set appropriate performance standards. i.e. functionality, reliability and survivability. Develop scheme to allow the independent competent body (ICB) to verify the design against the performance standards.
Create formal document distribution matrix to ensure all disciplines & departments receive all necessary design information in a timely manner.
Project Engineering Manager
3
Structural Integrity Interface
Ensure structural integrity interfaces are identified & visible to Project, e.g. HBP / Client focal points, Technical Authorities, Independent Verification Bodies, etc.
Structural
4
Material Selection Report
Report defining the requirements and specifications of necessary material.
Metallurgy
HBP Corporate Material Engineering Specifications.
5
Hazard Management Plan
Create Hazard Management Plan identifying all key hazards, technical safety activities and the approach to managing Major Accident Hazards (MAH) in the design.
Ensure PDMS catalogues are populated & available for all affected disciplines, utilising HBP Corporate data, i.e. CPC, where possible.
Engineering Systems, supported by Piping, Electrical, Instruments, Structural & HVAC
8
CMSS Philosophy
Develop Control Monitoring and Safety Systems (CMSS) Philosophy covering key instrumentation and control systems e.g. Process Control System (PCS), Emergency Shutdown System (ESD) and Fire and Gas (F&G).
Issue Hazardous Area Layouts for formal Inter-Discipline Review (IDC).
Technical Safety
9
Equipment List
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
10
Mechanical Handling Strategy
Develop Mechanical Handling Strategy including general approach / constraints, platform crane limits, installation philosophy, operation and maintenance, etc.
Mechanical and Structural
11
Particular Material Appraisals (PMA)
Where required, i.e. where Corporate PMA’s or EAM’s are not suitable, develop new PMA’s and obtain approval from Notified Bodies (NoBo’s).
PED Focal Point
12
Fire Risk Assessment (FRA)
Determine Fire & Explosion scenarios and identifies requirements for prevention, control and mitigation measures.
Technical Safety
13
Emergency Escape & Resecue Assesment (EERA)
Identify requirements for emergency escape & rescue, e.g. lifeboats, escape routes, plant layout, etc
Technical Safety
14
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 significant, to propose prevention or mitigating measures.
Technical Safety
15
Blast Design Philosophy
Develop philosophy that assesses potential explosion hazards and identifies appropriate blast loadings to be applied to the engineering design process, eg. Vessels, pipe supports, structural steel, etc.
Technical Safety
16
PFP / AFP Philosophy
Develop philosophy that identifies requirements for Passive Fire Protection (PFP) and/or Active Fire Protection (AFP).
Technical Safety
17
HIPPS Review
Initial review to establish requirements for a High Integrity Pressure Protection System.
Formal Engineering review of Plot Plans / Layouts. The review shall ensure that the layout design complies with the required technical, safety, operability and maintainability 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, (DOCUMENT CODE)
4
C&E Review
Formal review of Cause & Effects diagrams to confirm design basis and alignment with Hazard Management Plan.
Instruments, Process, Technical Safety
Hazard and Risk Management Procedure (DOCUMENT CODE); Engineering & Design reviews, (DOCUMENT CODE); Management of Functional Safety Guideline (DOCUMENT CODE)
5
Technical Audit
Obtain confirmation, by sampling of project documentation, that the engineering of the project is to the required standard and free from errors.
To ‘Freeze’ the Process design, and develop dependent design & procurement activities.
Activities / Deliverables
Description
Key Discipline
Supporting Documentation
1
PUWER Assessments
Conduct initial PUWER assessment typically by review of PDMS model and/or vendor / equipment supplier information received to date.
Technical Safety, Mechanical
Engineering & Design Reviews, (DOCUMENT CODE)
2
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, (DOCUMENT CODE); Engineering & Design Reviews, (DOCUMENT CODE) – Note: additional HAZOP’s may be required, i.e. earlier or later in the project. PEM to consult with Process & Technical Safety Lead Engineers.
3
SHE Audit (AFD)
SHE Audit ensures that the design obligations under The Health and Safety At Work Act 1974 and project health, safety and environmental performance standards are being or have been met during the engineering and design processes.
Issue final report to document & confirm that the design has considered all applicable environmental aspects & demonstrates that design controls have been included to minimise / control the environmental impact.
Technical Safety
Process Engineering & Design Reviews, (DOCUMENT CODE)
5
Constructability Review
Conduct formal Constructability Reviews to ensure safe and efficient installation of plant & equipment.
Affected disciplines + Construction / Implementation Group
Engineering & Design Reviews, (DOCUMENT CODE)
6
P&ID AFD
Issue Approved For Design (AFD) Process and Instrumentation 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, (DOCUMENT CODE)
12
HIPPS Study
Conduct study to formally identify the performance requirements of the High Integrity Pressure Protection System (HIPPS) and demonstrate that it is robust. Should include dynamic study for a range of transient conditions.
Process
Management of Functional Safety, (DOCUMENT CODE)
13
HIPPS Reliability Study
Conduct study to formally demonstrate that the High Integrity Pressure Protection System (HIPPS) complies with the reliability & availability criteria for the Project, e.g. as stipulated in the performance standards.
Instruments
Management of Functional Safety, (DOCUMENT CODE)
14
SIL Achievement Report
Conduct independent assessment to formally record that the target Safety Integrity Levels (SIL’s have been achieved) Must be completed prior to introduction of Hydrocarbons.
Independent Competent Person (ICP)
Management of Functional Safety, (DOCUMENT CODE)
15
Flow Assurance
Conduct flow assurance studies to demonstrate the process design under a range of flow conditions, i.e. start-up to 100%.
Process
16
Verification of Vendor Information & Certification – Design Completion
Verify, primarily through review of vendor documentation, that their design & manufacture of fabricated packages, etc is robust and contains sufficient information to facilitate completion of affected HBP discipline design.
Affected disciplines
17
PFEER Compliance Report
Issue final report as documented confirmation that the design meets the requirements of the Prevention of Fire and Explosion, and Emergency Response (PFEER) Regulations
Issue Approved For Construction (AFC) Piping Isometrics, Structural Steelwork drgs, etc.
Affected Disciplines
10
Verification of Vendor Information& Certification – Installation, Operation & Maintenance
Verify, primarily through review of vendor documentation, that their design & manufacture of fabricated packages, etc is robust and contains sufficient information to facilitate safe installation, operation & maintenance.
Affected Disciplines
11
EC Design Examination Certificates
Where HBP are deemed to be the manufacturer of the piping systems, then under the PED/PER, HBP have to apply to the Notified Body (NoBo) for an EC Design Examination Certificate (Cat IV assemblies only).
PER Focal point
Project Compliance with the Pressure Equipment Directive, Document No. (DOCUMENT CODE).
12
Declaration of Conformity
Where HBP are deemed to be the manufacturer of the piping systems, then under the PED/PER, HBP have to create a Declaration of Conformity, signed by the Project Manager.
Project Manager
Project Compliance with the Pressure Equipment Directive, Document No. (DOCUMENT CODE).
This workflow is a good practice guidance to Engineering Managers and supporting personnel 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:
Phase 1: Scope Definition and Engineering Execution Strategy
Phase 2: Commencement of FEED Design
Phase 3: Initial FEED Development and Hazard Identification
Phase 4: Initial Design Review & Audit
Phase 5: FEED Design Approval (AFD)
Phase 6: Final Reviews and Feed Report Compilation
The workflow shown in the follow Road Map illustrates the execution sequence on a generic FEED Project. The vertical columns show activities that can be undertaken concurrently whilst the sequential flow 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 workflow allows the risks of out-of-sequence working to be identified and the necessary mitigation strategies to be put in place.
HBP’s corporate governance and assurance of Engineering will measure compliance with the workflow and ensure out-of-phase working is being identified and managed. This document contains a copy of the FEED Road Map and includes detailed descriptions of the activities, the key engineering disciplines and supporting documentation. Phase 1: Scope Definition and Engineering Execution Strategy
Preparation for commencement of detail design. To evaluate FEED deliverables to ensure engineering is sufficiently mature for detail design to progress in a controlled and minimal change environment. To confirm Engineering Execution Plan.
Activities / Deliverables
Description
Supporting Documentation
1
Engineering Execution Plan & Engineering Organisation Chart
Create Engineering Execution Plan complete with key supporting documents / information.
2
Preparation/Validation of Conceptual Study Report/BoD
Confirm maturity of Conceptual Design report. Identify any areas of concern and ensure these are captured on the Technical Risk Register.
3
Project Baseline Standards
Establish which codes, standards and specifications are to be utilised, e.g.. Corporate, project, client, and confirm procedure. Include in Engineering Execution Plan and/or Discipline Job Design Specifications.
Create 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.
Create formal Technical Risk Register identifying all possible risks associated with the engineering design.
6
Integrated Engineering Systems
Agree engineering design tools to be used and confirm 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 specifications.
Engineering Systems Project Start-up Manual, Document No. (DOCUMENT CODE)
7
QRA & FRA Strategy
Establish status of project Quantitative Risk Assessment (QRA), Fire Risk Assessment (FRA) and Emergency Escape & Rescue Assessment (EERA) information and confirm methodology for timely delivery into engineering design process. Agree accountability for delivery, e.g.. Client, 3rd party, HBP, and record in Engineering Execution Plan.
Define the key project specific design parameters and operational constraints 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 Plan
Agree work breakdown structure, develop CTRs and create level 3 integrated engineering plan covering all disciplines. To be included in Engineering Execution Plan.
10
Confirm CE Compliance Strategy
Review and confirm strategy for CE Compliance. Ensure discipline Lead Engineers are aware of their responsibilities and appropriate resources / measures are in place.
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
1
Safety Critical Systems/Elements and Performance Standards
Confirm safety critical systems / elements and set appropriate performance standards. i.e. functionality, reliability and survivability.
Create formal document distribution matrix to ensure all disciplines & departments receive all necessary design information in a timely manner.
3
Structural Integrity Interface
Ensure structural integrity interfaces are identified & visible to Project, e.g. HBP / Client focal points, Technical Authorities, Independent Verification Bodies, etc.
4
Material Selection Report
Report defining the requirements and specifications of necessary material.
HBP Corporate Material Engineering Specifications.
5
Hazard Management Plan
Create Hazard Management Plan identifying all key hazards, technical safety activities and the approach to managing Major Accident Hazards (MAH) in the design.
Ensure PDMS catalogues are populated & available for all affected disciplines, utilising HBP Corporate data, i.e. CPC, where possible.
8
CMSS Philosophy
The purpose of this task is to define and prepare the assurance activities to be undertaken aligned with the project categorisation.
Develop Control Monitoring and Safety Systems (CMSS) Philosophy covering key instrumentation and control systems e.g. Process Control System (PCS), Emergency Shutdown System (ESD) and Fire and Gas (F&G).
Initial review to establish requirements for a High Integrity Pressure Protection System.
Instruments
Management of Functional Safety, (DOCUMENT CODE)
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 significant, 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 Materia Appraisals (PMA)
Where required, i.e. where Corporate PMA’s or EAM’s are not suitable, develop new PMA’s and obtain approval from Notified 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 formal Inter-Discipline Review (IDC).
Technical Safety
13
Fire Risk Assessment (FRA)
Determines Fire & Explosion scenarios and identifies requirements for prevention, control and mitigation measures.
Technical Safety
14
Blast Design Philosophy
Develop philosophy that assesses potential explosion hazards and identifies 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 specified duration when under attack by fire, explosion and toxic gases.
Technical Safety
Fire Hazards Assessment, Blast Assessment, Dispersion Assessment, Emergency, Escape and Rescue Assessment, Heat Stess Assessment
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
17
Emergency Escape & Rescue Assessment (EERA)
To identify requirements for emergency escape & rescue, e.g. lifeboats, escape routes, plant layout, etc.
Technical Safety
18
PFP / AFP Philosophy
Develop philosophy that identifies requirements for Passive Fire Protection (PFP) and/or Active Fire Protection (AFP).
Technical Safety
19
Power System Analysis
Check power system capacities for increase power requirements for new equipment (Brownfield).
Formal Engineering discipline review of P&ID’s to confirm 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 and maintainability 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, (DOCUMENT CODE)
4
C&E Review
Formal review of Cause & Effects diagrams to confirm design basis and alignment with Hazard Management Plan.
Instruments, Process, Technical Safety
Hazard and Risk Management Procedure (DOCUMENT CODE); Engineering & Design reviews, (DOCUMENT CODE); Management of Functional Safety Guideline (DOCUMENT CODE)
5
Technical Audit
Obtain confirmation, by sampling of project documentation, that the engineering of the project is to the required standard and free from errors.
To ‘Freeze’ the Process design, and develop dependent design & procurement activities.
Activities / Deliverables
Description
Key Discipline
Supporting Documentation
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 – (DOCUMENT CODE)
2
PUWER Assessments
Conduct initial PUWER assessment typically by review of PDMS model and/or vendor / equipment supplier information received to date.
Technical Safety, Mechanical
Engineering & Design Reviews, (DOCUMENT CODE)
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, (DOCUMENT CODE); Engineering & Design Reviews, (DOCUMENT CODE) – 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 environmental issues that have been considered as part of the process to select the final option from the various alternatives considered. Thus preventing, or eliminating, or where the alternatives are not practicable, to then limit or reduce environmental impacts associated with the selected option.
Technical Safety
Procedure for Selection of Best Available Techniques (BAT) Procedure No: (DOCUMENT CODE)
5
Constructability Review
Conduct formal Constructability Reviews to ensure safe and efficient installation of plant & equipment.
Affected disciplines + Construction / Implementation Group
Engineering & Design Reviews, (DOCUMENT CODE)
6
P&ID AFD
Issue Approved For Design (AFD) Process and Instrumentation 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, (DOCUMENT CODE)
12
HIPPS Study
Conduct study to formally identify the performance requirements of the High Integrity Pressure Protection System (HIPPS) and demonstrate that it is robust. Should include dynamic study for a range of transient conditions.
Process
Management of Functional Safety, (DOCUMENT CODE)
13
Qualitative Risk Assessment (QRA)
Multi-disciplinary study of hazards, the likeihood of their occurrence 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 Stess Assessment
14
HIPPS Reliability Study
Conduct study to formally demonstrate that the High Integrity Pressure Protection System (HIPPS) complies with the reliability & availability criteria for the Project, e.g. as stipulated in the performance standards.
Instruments
Management of Functional Safety, (DOCUMENT CODE)
15
Flow Assurance
Conduct flow assurance studies to demonstrate the process design under a range of flow 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 EDAS requirements and adequately explain how those requirements are being fulfilled.
