Feed Phase Engineering Design Integrity

FEED Phase Engineering Design Integrity Workflow

Introduction FEED Engineering Design Integrity Workflow (EDIW) EDIW is AMEC’s best 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: 1 Scope Definition and Engineering Execution Strategy 2 Commencement of FEED Design 3 Initial FEED Development and Hazard Identification 4 Initial Design Review & Audit 5 FEED Design Approval (AFD) 6 Final Reviews and Feed Report Compilation The workflow 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 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 EDIW allows the risks of out-of-sequence working to be identified and the necessary mitigation strategies to be put in place. AMEC’s corporate governance and assurance of Engineering will measure compliance with the EDIW workflow and ensure out-of-phase working is being identified 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.

1

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.

Engineering Baseline Standards, Document No. OAG-X160-190-GDL-012 (previously AOD-92043 )

4

Engineering Audit Schedule

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.

Technical Safety Events Schedule (Lead Technical Safety Engineer)

5

Technical Risk Register

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. 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 confirm methodology for timely delivery into engineering design process. Agree accountability for delivery, e.g.. Client, 3rd party, AMEC, and record in Engineering Execution Plan.

Hazard Management Philosophy, OAG-X160190-GDL-009 (previously AOD-97-001): Hazard & Risk Management, OAG-X160-190-PRO-024

8

Discipline Job Design Specification

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.

Corporate CE Compliance Strategy OAGX160-190-MAN-001; Project Compliance with Pressure Equipment Regulations OAG-X160050-PRO-001; Pressure Equipment Regulations Guidelines AOD-97-047; ATEX Guidelines, OAG-X160-190-GDL-003; Machinery Directive Guidelines, O&G-ENG-REP-29-001; Electromatic Compatibility Regulations Guidelines, OAG-X160-190-GDL-003; MC, The Electrical Equipment (Safety) Regulations Guidelines, OAG-X160-190-GDL-003.

11

Prepare Interface Register

Develop interface register to ensure all interfaces are identified and managed.

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

2

Phase 2

Commencement 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 Hazard Management Philosophy, OAG-X160190-GDL-009 (previously AOD-97-001); Hazard & Risk Management, OAG-X160-190-PRO-024; Design Verification Activities (under DCR), OAGX160-190-PRO-028; Platform Safety Case.

1

Safety Critical Systems/ Elements and Performance Standards

Confirm safety critical systems / elements and set appropriate performance standards. i.e. functionality, reliability and survivability.

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 Integrity Interface

Ensure structural integrity interfaces are identified & visible to Project, e.g. AMEC / Client focal points, Technical Authorities, Independent Verification Bodies, etc.

4

Material Selection Report

Report defining the requirements and specifications of necessary material.

AMEC 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.

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

6

Piping Specifications

Develop / confirm baseline piping specifications, utilising AMEC Corporate specifications where possible.

AMEC Corporate Piping Specifications.

7

PDMS Catalogues

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

8

3

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).

Phase 3

Initial Design Development and Hazard Identification To develop initial design deliverables to Inter Discipline Review (IDC) stage and identify key hazards. Activities / Deliverables

Description

Key Discipline

Supporting Documentation

1

HAZID

Perform hazard identification studies, as identified on Engineering Audit Schedule / Technical Safety Events Schedule.

Technical Safety

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

2

ENVID

Formal assessment of environmental aspects associated with a modification or a change, and to propose prevention or mitigating measures.

Technical Safety

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

3

PFD IDC

Issue Process Flow Diagrams (PFD’s) on formal Inter-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 formal inter-Discipline Review (IDC).

7

HIPPS Review

Initial review to establish requirements for a High Integrity Pressure Protection System.

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

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).

Electrical

20

Preliminary Weight Report

Prepare preliminary Weight report.

Structural

Piping and Layouts Instruments

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

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

4

Phase 4

Initial Design Review and Audit To confirm that the initial design development is robust. Activities / Deliverables 1

Hazardous Area Review

Description

Key Discipline

Formal Engineering discipline review of hazardous area layouts to confirm requirements for the correct selection and location of equipment.

Technical Safety

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

Process, Piping, Technical Safety, Instruments

P&ID Review

Formal Engineering discipline review of P&ID's to confirm design basis.

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.

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

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.

Independent (Corporate Engineering)

Technical Audit Procedure OAG-X160-190-PRO-022

2

3

5

Piping and Layouts, Structural, Mechanical, Electrical, Technical Safety, Process

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

Phase 5

FEED Design Approval (AFD) To ‘Freeze’ the Process design, and develop dependent design & procurement activities. Activities / Deliverables

Description

1

Final Design review

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

2

PUWER Assessments

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

Key Discipline

Supporting Documentation

Technical Safety

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

Technical Safety, Mechanical

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

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-X160-190PRO-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 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: OAG-X160-190-PRO-030

5

Constructability Review

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

Affected disciplines + Construction / Implementation Group

6

P&ID AFD

Issue Approved For Design (AFD) Process and Instrumentation Diagrams.

7

C&E AFD

Issue Approved For Design (AFD) Cause & Effects.

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 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, OAG-X160-190-GDL-005

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.

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

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 Criteria appropriate for Project Category.

Engineering Management

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 fulfilled.

Engineering Management

3

17

Engineering & Design Reviews, OAG-X160-190-PRO-014

Process Instruments

Technical Safety

Fire Hazards Assessment, Blast Assessment, Dispersion Assessment, Emergency, Escape and Rescue Assessment, Heat Stess Assessment Management of Functional Safety, OAG-X160-190-GDL-004

6

Phase 6

Final Reviews and FEED Report Compilation To ensure all final design deliverables are completed and that client and statutory obligations are satisfactorily resolved. Activities / Deliverables

1

FEED Report

Description

Collate all discipline inputs and finalise study report.

Key Discipline Project Management

Supporting Documentation All Discipline Reports and discipline drawings etc.

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