GR-TEG1-1000-004 Guide Line For Engineering Instruction To Construction PDF

 

  Security Level 2 G

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1-1000-004  ISSUED  AUG.16,’11  

ENGINEERING GUIDE FOR PROCESS PLANT

DESIGN GENERAL

GUIDELINE FOR ENGINEERING INSTRUCTION TO CONSTRUCTION

Unless stamped “CONTROLLED”, any hard copy from TEC-STANDARD database is handled as “Non-controlled”. Users should confirm any time that the copy is the latest version.

 L  TOYO ENGINEERING CORPORATION  TOKYO

GR-TEG1-1000-004h.doc

JAPAN

 

 

Security Level 2

 

TOKYO

 L 

 

JAPAN

 TOYO ENGINEERING CORP. 

ISSUED

ENGINEERING GUIDE FOR PROCESS PLANT

DESIGN GENERAL GUIDELINE FOR ENGINEERING INSTRUCTION TO CONSTRUCTION 

AUG.16,’11 

G

R-T

E

1-1000-004 

PAGE 

1

OF 

CONTENTS

1.  GENERAL

2 

1.1 

Objectives

2 

1.2 

Scope

2 

1.3 

Application Notes

2 

1.4 

References

2 

GUIDELINE

2 

2.  2.1 

List of Engineering Instruction to Construction

2 

2.2 

Cover Sheet

2 

Appendix (1)  List of Engineering Instruction to Construction Appendix (2)  Sample of cover sheet

History (P.1/1)

GR-TEG1-1000-004.doc

G 

(P.1/3-3/3) (P.1/1)

2

 

 

Security Level 2

 

TOKYO

 L 

 

JAPAN

 TOYO ENGINEERING CORP. 

ISSUED

ENGINEERING GUIDE FOR PROCESS PLANT

DESIGN GENERAL GUIDELINE FOR ENGINEERING INSTRUCTION TO CONSTRUCTION 

AUG.16,’11 

G

R-T

E

G 

1-1000-004 

PAGE 

2

OF 

2

1.  GENERAL 1.1 

Objectives

This guide defines the process of issuing Engineering Instructions, including content and timing, from each engineering disciplines to construction division. There exists established procedures to issue deliverables such as P&ID, Data Sheets, and drawings. However, no  procedures are available to issue Engineering Instruction to Construction. As a result, sometime such instructions are prepared based on each assign engineer's understanding and issued by Letter Management System (LMS). This guide aims to eliminate such non-uniformity of each assign engineer's manner, and to provide them a satandardized procedure to issue applicable Engineering Instruction to Construction in timely manner. 1.2 

Scope

This guide is applied for all EPC projects in principle, except for cases where construction is out of scope. For any project's specific deviation/exception to this guide, it is necessary to be approved by General Manager of each engineering division. 1.3 

Application Notes

This guide is limited to the internal use in Toyo between engineering disciplines and construction division. Third  party such as client, subcontractors and JV/Consortium JV/Consortium Partner Partnerss is not supposed to be included. Even though for internal use, the instructions shall be written as considering the quality of expression in instructions shall be described as a third party's understand level. For specific project requirement, handling and distribution of instructions to a third party shall be determined and approved by construction division. In addition, this guide shall be customized to suit specific project's contract requirements. 1.4 

References

Following Toyo-Japan's standards are used as reference in this guide. Each Global Toyo company shall refer comparable local standards and guides. TMS0-101 : TMS1-10002 TMS1-100 02 : TMS1-10003 TMS1-100 03 : TMS1-10401 TMS1-104 01 : GM-TEG1-6220-203GM-TEG1-62 20-203-1: 1: 2.  2.1 

DESIGN CONTROL [C.Q.P] WORK EXECUTION PROCEDURE FOR ENGINEERING DESIGN COMMON AUTHORIZATION STANDARD FOR ENGINEERING DESIGN CONTROL OF DOCUMENT & DATA FOR ENGINEERING DESIGN DOCUMENT CONTROL PROCEDURE

GUIDELINE List of Engineering Instruction to Construction

Instruction items, timing of issue and issue forms of Engineering Instruction to Construction are specified in Appendix(1). 2.2 

Cover Sheet

Engineering Instruction to Construction shall be issued with cover sheet. Sample of cover sheet is attached in Appendix(2).

GR-TEG1-1000-004.doc

 

Appendix 1) List of Engineering Instruction to Construction Before AFC

Disciplines Process

Facilities Engineering Division

Instruction Items Th Thee sco scope pe of ch chem emic ical al cl clea eani ning ng

Timing of Issue Afte Afterr iss issua uanc ncee of of AFC AFC  P&ID The scope of built iitt cl clean Before construction ooff    piping System boundary& boundary& schedule for M/C After issuance issuance ooff AFP   P&ID  Arrangement of temporary temporary facilities facilities Before implementation of pre-commi./ for pre-commi./commissioning com commis missio sionin nin act activ ivit it activit Preservation procedure for Prior to intermission of  suspension of project construction The scope of water prohibited piping against pressure test Flushing concept including scope of  permanent and temporary facility which will be utilized  Arrangement of temporary temporary valve and and piping for pre-commi./ pre-commi./commissioning commissioning activity

Before issuance of  AFP P&ID  After issuance issuance of AFC   P&ID

Cons Constr truc ucti tion on BQ for for pla plann nnin ing g

Afte Afterr rec recei eivi ving ng vend vendor or quotation, or earlier stage by In-house estimation  Vendor document document check

 Vendor erection erection manual and and other key documents for handling and erection at site such as GA with weight, shipping sketch, erection spare parts list, site preservation roce rocedure dure etc. List of key documents for construction such as package equipment plot plan, GA with weight, shipping sketch, erection spare parts list, site preservation preservation procedure,  Vendor document document list, etc.

P re

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    - lighting     - Motor RCU     - cable tray   - Pre-fabricated Pre-fabricat ed pipe spools and pipe in commercial length for interconnecting piping

Project procedure  

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Engineering Instruction (Marked-up P&ID) Engineering Instruction

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Engineering Instruction

Before implementation of pre-commi./ commissioning commissioni ng activity

 

Engineering Instruction ●

ID check or Vendor document distribution

Preliminary: After 1st issue of the key documents, Final: Equipment FOB

Engineering Instruction (Summary Table)  

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Engineering Instruction (Summary Table)

 

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Prior to start of  construction work. Prior to start of  construction work. Prior to start of  construction work.

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Supply split between Equipment components supplied by different fabricators. Supply split between Equipment and Prior to start of  construction work. the following: - Mechanical Erection - Piping Work - Electrical Work - Instrument Work

     

 

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For sche schedul dulee and manning Prior to start of  construction work.

￬ ￬ (with sketch)

   

   

Preliminary: After 1st issue of the key documents, Final: Equipment FOB

 

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GR-TEG1-1000-004a1.xls

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Weldi ng rods for field welding     -- Welding Insulation, Insulation, steam trace     - Touch-up paint     - Construction Construction sp spare are parts Special notes for construction such as PWHT by process reason, bolting by torque wrench or bolt tensioner, special preservation if required, etc.

- Civil Work - Insulation Work - Painting Work Critical specifications required to achieve performance General construction requirement for safety and quality Feedback from TOYO construction for similar plant.

 

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Engineering Instruction (List) ●

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Communication Communicatio n channel with Vendo Vendorr Equipment FOB

Equipment

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￬ ￬ ￬ ￬

Requi Requirem rement ent ooff Ve Vendo ndorr superv superviso isorr

Issue Form Engineering Instruction (Marked-up P&ID) Engineering Instruction (Marked-up P&ID) Engineering Instruction (Marked-up P&ID) Engineering Instruction

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Scope of accessories and construction Preliminary: After 1st material, and their supply condition issue of the key documents, Final: Equipment FOB   - Anchor bolts/nuts and template template     - Liner plates, plates, jack jack bolt, eetc. tc. for leveling of equipment   - sliding sliding plate plate for horizontal equipment   - Initial filling of lubricant, lubricant, Flushing oil   - Lifting beam, wire, & shackle     - Instrument/Electrica Instrument/Electricall components components and their wiring/tubing

After AFC

PreAFP  AFD AFC comm

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Engineering Instruction (List) Engineering Instruction Engineering Instruction

 

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Engineering Instruction

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Engineering Instruction Engineering Instruction Engineering Instruction

Remarks

Security Level 2 GR-TEG1-1000-004 Appendix(1)-1/3

 

Appendix 1) List of Engineering Instruction to Construction Before AFC

Disciplines Equipment (cont.) Elec.

Instruction Items Timing of Issue Prior to start of  Requirement by Licensor, Requirement of inspection and record construction work. prior to commissioning commissioning  At KOM with with Drawing list and formats of  subcontractor (Before drawings, requisition list, delivery construction schedule, pre-commiss pre-commissioning ioning commencement at requirements, progress control key latest) B/Q, as-built information requirements  Any specific specific requirements requirements (e.g. change of types of materials, special details not covered in Typical, etc.)

Before applicable construction commencement

Control &

Change items* on delivered control

Before commencement

Instrumentati on Engineering Division

of final system equipment, field and and testsite inspection instrumentation devices associated materials (*Change items of which change (replacement, (replacement, modification, etc.) will be carried out at site after delivery delivery). ).

Pre

 

After AFC

Pre AFP  AFD  AFC comm

●

Engineering Instruction

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Engineering Instruction ●

Engineering Instruction

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Punch items* at Factory Acceptance  After completion completion of  Test (FAT) of control systems control systems’ FAT (*Punch Items of which close out will be carried over to site). Civil and  Architectural Engineering Division

Issue Form Engineering Instruction

Engineering Instruction ●

Category-1 ; Instruction about construction sequence of structures. Category-1   Special considerati on from view point of structural structu ral design and installati on of other facilities.   Engineering Instruction Time of relevant AFC Timing of concrete slab casting for   ● drawing issuance electrical panel supporting floor in substation. Engineering Instruction Time of relevant AFC Equipment support structure and   ● equipment installation. (specially for drawing issuance complicated complicate d large scale structure) Pipe Pipe rack rack and and pip pipee ins insta tall llat atio ion. n. Ti Time me of rele releva vant nt AF AFC C Engineering Instruction   ● drawing issuance Engineering Instruction Required construction sequence by Time of relevant AFC   ● structural design. drawing issuance Engineering Instruction Time of relevant AFC drawing issuance or ● one(1) month before relevant construction starting Category-2 Category2 ; Instruction about construction tolerance/accuracy. tolerance/accuracy.   Special consideration from view point of applicable code, process scheme and structu structural ral design.)

Project specific item and others, if  any.

Road location, road width and road head clearance Wall thickness and Internal dimension of pit/dike/spill wall/etc.

Time of relevant AFC drawing issuance Time of relevant AFC drawing issuance

Elevation of top of beam for RC pipe rack Location of equipment foundation/structure foundation/s tructure where large size piping tightly connects to equipment.

Time of relevant AFC drawing issuance Time of relevant AFC drawing issuance

Project specific item and others, if  any.

Time of relevant AFC drawing issuance or one(1) month before relevant construction

 

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Engineering Instruction Engineering Instruction Engineering Instruction Engineering Instruction

Engineering Instruction ●

starting Category-3 Category3 ; Special notice about method control) of construction Bench mark(s) of surveying

Subsoil for foundations (incl. piling foundation) Piling

Heavy welding on insert plate (control of welding heat input)

One(1) month before Civil construction starting One(1) month before Civil construction starting One(1) month before Civil construction starting one(1) month before relevant construction starting

Time of relevant AFC drawing issuance or one(1) month before relevant construction starting Engineering Instruction for Fire Within one month after Protection System Summary submission of AFC P&ID Engineering Instruction for Filed Within one month after Fire Fighting Equipment Installation submission of AFC fire fighting equipment layout

Engineering Instruction ●

Engineering Instruction ●

Engineering Instruction ●

Engineering Instruction ●

Engineering Instruction

Project specific item and others, if  any.

HSE Engineering

Engineering Instruction for Building Within one month after Fire Fighting System Installation submission of AFC P&ID GR-TEG1-1000-004a1.xls

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Engineering Instruction ●

Engineering Instruction ●

Engineering Instruction ●

Remarks

Security Level 2 GR-TEG1-1000-004 Appendix(1)-2/3

 

Appendix 1) List of Engineering Instruction to Construction Before AFC

Disciplines Piping

Instruction Items Timing of Issue P re AFP AF D Category-1 Category1 ; Piping Field Instruction to be issued to Construction Group  Vendor's Deviations Deviations in Pipe Wall  After purchase purchase order Thickness ●

After AFC

PreAF C comm

Engineer Engi neering ing Ins Instructi truction on

 Vendor's Deviations Deviations in Delivered Pipe After purchase purchase order Length

Pip Piping ing M Mate ateria riall Sub Substi stitut tution ion Plan Plan

Issue Form

● ●

Engineer Engi neering ing Ins Instructi truction on ●

● ●

After After is issua suance nce of pipi piping ng isometric drawings.

 After purchase purchase order

 After purchase purchase order

Engineer Engi neering ing Ins Instructi truction on

Provide Provide the inform informatio ation n about the sc scope ope of su supply pply for bolts / nuts at the special tie-in applicati applications ons such as PSV inlet, tapped holes on the special valves and special equipment nozzles. For these applications, it is difficult to identify the scope of  supply by referring only piping isometric drawings. (As neces necessar sary;) y;) Provide the information about the scope of supply / work by the cathodic protection vendor, in order to decide the scope of work and supply by the construction contractor.

Eng Engine ineeri ering ng Ins Instru tructi ction on ●

Category-2 Category2 ; Piping Field Instruction to be issued after confirmation with Construction Group BOM Node Structure in Material When the project starts Engineer Engi neering ing Ins Instructi truction on Management System (SP-Mat) ●

BOM to be controlled in Material Management System (SP-Mat)

When the project starts

After After purcha purchase se orde orderr

Confirm Confirm and and decide decide the b bulk ulk ite item m NOT control controlled led by ident level (i.e. controlled by lot level), such as pipe support structural steel and spool piping systems etc.

Engineer Engi neering ing Ins Instructi truction on

Provide Provide data data shee sheett for pip piping ing spe special cial bolts bolts / nuts to supplement the "description" "description" in the BM sheet, since it is difficult to identify the detailed information of these bolts / nuts by referring only the description in the BM sheet, such as length and applicable location etc.. (Note; For special bolt "SBS" based on piping MTO, UNIT of special bolt will be specified as "set" due to MMS system limitation. Instead, the numbers of required pieces will be included into material description. ) Confirm Confirm and and decide decide the sc scope ope of ssuppl upply y for the support materials, i.e. construction sub-contractor or Toyo's engineering. In addition, engineering shall clarify the delivery condition of the pipe support materials, such as clamp shoe, or U-band support etc.

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Scope of Supply for Pipe Support Materials

Minutes of meeting

Engineer Engi neering ing Ins Instructi truction on

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Construction Document for Special Piping System (such as GRP, lining piping etc.)

Construction Document for Duct / Chute System (Urea/Granulation (Urea/Granulation Unit)

 After purchase purchase order (before the contract with construction sub  con)

 After purchase purchase order (before the contract with construction sub  con)

(As neces necessar sary;) y;) Provide the instruction about the contents of  construction document, and the scope of material supply and work by vendor, since the scope of  supply and work are sometimes split into several parties (i.e. several vendors and Toyo).

Eng Engine ineeri ering ng Ins Instru tructi ction on

(As neces necessar sary;) y;) Provide the instruction about the contents of  construction document, and the scope of material supply and work by vendor, since the scope of  supply and work are sometimes split into several parties (i.e. several vendors and Toyo).

Eng Engine ineeri ering ng Ins Instru tructi ction on

(As neces necessar sary;) y;) Discussed and confirm the necessity of the PWHT procedure for Cr-Mo steel at site, in order to avoid applying the higher temperature for site PWHT than the one for tempering by material supplier.

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GR-TEG1-1000-004a1.xls

Eng Engine ineeri ering ng Ins Instru tructi ction on

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Post Weld Heat Treatment of Cr-Mo  After purchase purchase order Steel

Confirm Confirm and and decide decide the a appro ppropria priate te BOM node node structure between construction and engineering in order to suit to the project organizati organization on and the warehousing system at site.

Engineer Engi neering ing Ins Instructi truction on ●

Da Data ta S Shee heett fo forr Speci Special al Bolt Bolts/N s/Nuts uts

Inform Inform the ven vendor' dor's deviatio deviations ns in the p pipe ipe w wall all thickness for material control in the material management system (SP-Mat in Toyo's standard). If any deviations in the pipe wall thickness, discrepancies discrepanci es between the actual item and the ident code information would be observed in the warehouse, that will confuse the material control at site. Inform Inform the devi deviatio ations ns in the del deliver ivered ed pip pipee lengt length h for BQ calculation and weld mapping by construction. (Note; Toyo's standard requirements in the delivered length is specified in the requisitions.) Inform Inform the pla plans ns of the h highe igher-gr r-grade ade mater material ial substitutions for the lower-grad lower-gradee applications of  piping materials, that was intended when deciding order quantities for purchasing.

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Scope of Supply / Work for Cathodic Protection System

Remarks

Engineer Engi neering ing Ins Instructi truction on ●

Scope of Supply for Bolts/Nuts at Special Tie-in Applications

Security Level 2 GR-TEG1-1000-004 Appendix(1)-3/3

 

Security Level 2 GR-TEG1-1000-0004 Appendix(2)-1/1

xxx x PROJECT xxxx MTPD xxxx xxxxx xxx PLANT Doc. No No : xxxxxx xxx

ENGINEERING INSTRUCTION TO CONSTRUCTION CONSTRUCTION

Job No

: xxxxxxxx xxxxx

Rev. No.: 0

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CONT CO NTRACT RACTOR OR

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PROJECT TITLE

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LOCATI LOC ATION ON

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JOB NO NO..

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Page 1 of 1 

PROJECT

Sample REV. NO

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03/06/2011

DESCRIPTION DESCRIPTION

Preliminary Issue

GR-TEG1-1000-004a2.doc

PREP’D

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APP’D

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AUTH’D

 

Security Level 2 ENGINEERING GUIDE FOR PROCESS PLANT

 L 

 

TOKYO

 

JAPAN

 TOYO ENGINEERING CORP.

 

DESIGN GENERAL GUIDELINE FOR ENGINEERING INSTRUCTION TO CONSTRUCTION

ISSUE DATE ISSUE GRADE AUTHORIZATION

GR-TEG1-1000-004 HISTORY PAGE

 

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DESCRIPTION

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AUG.16,'11  Newly Established Engineering Management Div.

(1) Background and Reasons for Establishment (a) To clearly define the list of Engineering Engineering Instruction Instruction to Con Construction. struction. (2) Department and Author Engineering Management Division / T. Osanai, (3) Consultant Engineering Management Unit / M. Hamamura, H. Kasai, K. Ishii, I. Fukasawa, T. Nemura, S. Yamazaki, S. Shouji

GR-TEG1-1000-004r.doc