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PROCESS PLANT ENGINEERING ACTIVITY MODEL

Process Plant Engineering Activity Model


The information in this document is subject to change without notice.
Copyright Notice
The copyright of the contents of this document is assigned to the Process Industries STEP Consortium and its successors. However the
contents may be freely distributed or copied, in full or part, provided due acknowledgement is made.
Acknowledgements
The following organisations provided the information that was used to generate the model and reviewed the model at various stages of its
production.
AMEC Engineering Ltd
AKZO Engineering bv
British Nuclear Fuels plc
Eutech Engineering Solutions Ltd
Harrow Associates
ICI Engineering Ltd
Ingevision Framatome Systems dInformation
John Brown Engineers & Constructors Ltd

Lloyds Register of Shipping


Nuclear Electric plc
National Institute for Standards & Technology
Process Industries STEP Consortium (PISTEP)
Shell International
SINTEF
The British Petroleum Company plc
University of Newcastle upon Tyne

Introduction
This model and its associated documentation has been produced as an aid to those involved in the production of Application Protocols for the Process
Industries in the STEP (ISO 10303) standard. It provides an overview of the main activities and data flows associated with the life cycle of process plant.
It is emphasised that the aim of the model is not completeness but communication to those who require to understand the main interactions between the
major phases of engineering activities in the process plant life cycle. With this aim only the major data flows are shown and minor data flows and feeds
back to earlier phases of the life cycle have been ignored. The activities are depicted as serial streams for the process and engineering activities. However,
the activities may be ignored, combined or performed concurrently dependent upon the requirements of the task to be undertaken.
The model will be made available in four forms, a paper document (this document), an electronic version of this document in Microsoft Word for
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Windows version 3.0 or 6.0 or Wordperfect 5.1 for DOS, a Microsoft Powerpoint file suitable for version 3.0 or 4.0, a coloured wall chart (A0) and a
Microsoft VB basic program. Copies may be obtained from The Process Industries STEP Consortium at:
QMS
Beech House
1 Yorktown Road
Sandhurst
Camberley
Surrey
GU17 8DX
United Kingdom

Contact:
Telephone:
Facsimile:

W R Mesley
01252 878482 (Outside UK: +44 1252 878482)
01252 877386 (Outside UK: +44 1252 877386)

Purpose
To identify the activities which create and use engineering data that we wish to share and exchange in the Process Industries.
Something that engineers in the Process Industries will readily understand and identify with.
Viewpoint
A Plant Operators view based upon the Facility and Equipment life cycle.

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2

Microsoft, Word for Windows, Powerpoint and VB basic are registered trade marks and products of the Microsoft Corporation.
Wordperfect is a registered trademark of the Wordperfect Corporation.
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Context Statement
This activity model provides a simplified view of the Process Plant Life Cycle activities and indicates areas of interest and data flows that may be modelled
in a more formal manner. As such this model should prove useful in planning and developing Application Protocols to meet the needs of the Process
Industries within the ISO 10303 (STEP) environment.
Exclusions and Inclusions
The model excludes:
! 1. Design and manufacture of standard parts. e.g. Pumps, valves etc.
! 2. Development, Marketing and Transportation (other than pipelines) of manufactured product.
! 3. General Management activities.
! 4. The management of human resources and the supply of computing services.
! 5. Minor data flows. e.g. Minor Feedback's etc.
The model includes:
! 1. Engineering management activities.
! 2. Authorisations and Permissions both internal and external. e.g. License to Operate

PROCESS PLANT ENGINEERING ACTIVITY MODEL

Safety & Environment Case

MANAGEMENT ACTIVITIES
SET ENGINEERING
POLICY &
STANDARDS

PRODUCE & MAINTAIN


FEASIBILITY &
FINANCIAL CASE

CONTROL OPERATIONS
& ENGINEERING
ACTIVITIES

OBTAIN AGREEMENT
WITH REGULATORY
BODIES

REGULATORY BODIES
Regulatory Requirements
Authorizations

Process Definition
Control Philosophy
Costs, Benefits & Timings
Safety / Regulatory Requirements

PRODUCE
CONCEPTUAL
PROCESS DESIGN

Performance Requirements
Operating Procedures
Operating Conditions
Alarm / Trip Settings
Safety and Environment Case

PRODUCE DETAILED
PROCESS DESIGN

Process Stream Data


Process Flow Diagrams
Costs, Benefits & Timings

Detailed Process Design


Availability Requirements
Safety Systems Specifications
Operating Procedures
Codes & Standards

Preliminary Engineering Design


Engineering Philosophies
Availability Requirements
Cost & Time Estimates
Safety / Regulatory Requirements
Codes & Standards

PRODUCE CONCEPTUAL
ENGINEERING DESIGN

COMMISSION PROCESS
& HANDOVER PLANT

As Built Drawings
Equipment Commissioning Procedures
Equipment Operating Procedures
Inspection & Testing Records
Handover Certification
Detailed Engineering Design
Equipment Procedures
Vendor Drawings
Spares Lists

Equipment Procedures
Delivery Dates
Vendor Drawings
Certification
Equipment & Materials Catalogues
Invoices
SUPPLIERS
&
FABRICATORS

Delivery Dates Vendor


Drawings Certification
Equipment Procedures
Equipment & Materials
Catalogues

Plant Status
Ground Drains Status
Safety Case
As Built & As Modified Drawings

OPERATE
PLANT

Inspection Requirements
Work Permit Requests
Notification of Work
Completion

As Built Drawings
As Built Equipment Specifications
Spares Lists
Installation Procedures
Maintenance Procedures
Inspection Results
Unfinished Work Details

Delivery Dates Vendor


Drawings Certification
Equipment Procedures
Equipment & Materials Catalogues
Inspection Results
Shipping Details

DECOMMISSION
PLANT

Plant Status
Plant Records
Inspection Requirements
Regulatory Approvals

Engineering Work Requests


Working Conditions Requirements
Engineering Work Permits
Acceptance of Engineering Work

CONSTRUCT &
PRE-COMMISSION
PLANT

PRODUCE DETAILED
ENGINEERING
DESIGN
Materials & Equipment
Requirements & Specifications
Required on Site Dates

Materials & Equipment


Requirements &
Specifications
Required on Site Dates
Inspection Results
Shipping Details
Payment Details

As Built Drawings
Operating Procedures
Acceptance Test results
Handover Certificate

State of Equipment
Value of Equipment
Equipment Records

MAINTAIN
EQUIPMENT

DEMOLISH PLANT &


RESTORE SITE

Materials & Equipment


Requirements & Specifications
Required on Site Dates

Disposal Records
Restoration Records
Handover Records
Final Regulatory Approvals

PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES

P Harrow colact1 PISTEP 10/06/94

OVERVIEW
This diagram gives an overview of the whole life cycle and shows the relationships and data flows for the level 1 activities.
1. Set Engineering Policy and Standards
Defines the engineering policy that shall be used and obtain any
codes and standards that may be required.
2. Produce and Maintain Feasibility and Financial Case
Produce and maintain the feasibility and financial case.
3. Control Operations and Engineering Activities
Prepare plans, aquire resources to execute them, check
conformance to plan and take corrective action.
4. Obtain agreement with Regulatory Bodies
Obtain agreement with regulatory bodies for the siting, design,
construction, commissioning and operation of the plant. The
engineering management activities required to obtain approval
from the regulatory bodies for the mothballing of the plant or its
demolition and subsequent site restoration.
5. Regulatory Bodies
The external regulatory bodies whose requirements must be met
at all stages of the plant life cycle. These bodies may be a
purchaser of the plant, governmental body or supra-national
organisation at various stages of the plant life cycle.
6. Produce Conceptual Process Design
Produce the preliminary Process design which will be passed to
Conceptual Engineering Design and Detailed Process Design. It will
also prepare a feasibility and financial case for management.

7. Produce Conceptual Engineering Design


Produce the preliminary engineering philosophies to be used
and the preliminary engineering design required for further
detailed engineering design.
This activity is often performed concurrently with the
Conceptual Process design.
8. Produce Detailed Process Design
Produce the detailed process design which provides the
specifications, requirements, codes and standards, design and
operation philosophies required for the Detailed Engineering
Design and Commissioning.
9. Produce Detailed Engineering Design Produce the Detailed
Mechanical, Electrical, Control/Instrumentation, Plant/Building
Services and Civil/Structural Engineering Design for the plant
including all specifications, drawings, construction and
commissioning plans,
3D models, materials takeoff and spares lists.
10. Procure and Control Equipment Materials and Services
Make enquiries, place purchase orders, inspect and expedite
progress, ship goods and control stock of equipment and
materials.

11. Construct and Pre-Commission Plant


Construct the plant as defined by the detail design specifications
to plan to meet the needs of the commissioning team.
Construction includes verification that the design has been
satisfied and that the resulting plant is acceptable to the
commissioning team.
12. Commission Process and Handover Plant
Prove the operation of all plant systems as defined by the
detailed design specifications such that the plant can be
accepted for operation to manufacture product.
Commissioning typically consists of a number of stages
progressing from activities using either no or inert process
materials to the use of production process materials.
13. Operate Plant
Operate the plant safely, efficiently, and according to plan.
14. Maintain Equipment
Maintain the plant and equipment in a safe manner to ensure
plant operability.
15. Decommission Plant
Taking a plant out of operating service, isolating all feedstock
and services, removing all process materials from the plant, and
establishing maintenance conditions such that the plant could be
returned to operating service.

16. Demolish Plant and Restore Site


The activity of demolishing the plant and restoring the site.
Demolish Plant and Restore Site makes use of Plant Status from
Decommission Plant, and Equipment Status from Maintain
Equipment.
17. Suppliers and Fabricators
External suppliers and fabricators offering goods and services.

PRODUCE CONCEPTUAL PROCESS DESIGN


Define
Overall
Requirement

Identify
Candidate
Processes

Define End
Requirements

Identify Start Conditions


- Define Battery Limits
- Identify state of Plant
to be modified

Design
Process

Provide Input to
Feasibility /
Financial Case

Identify Safety /
Regulatory
Requirements

PRODUCE
DETAILED PROCESS
DESIGN

Define Unit
Operations
Produce Energy /
Mass Balance
Produce Composition
of Process Streams
Define Control
Philosophy

Process Definition
- Process Stream Properties
& Composition
- Required Unit Operations
- Process Flow Diagrams
- Energy Balance
Control Philosophy
Costs, Benefits & Timings
Safety / Regulatory Requirements

Produce Process
Flow Diagrams

Process Stream Data


Process Flow Diagrams
Costs, Benefits & Timings

PRODUCE CONCEPTUAL ENGINEERING DESIG


N

P Harrow colact1 PISTEP 26/04/94

CONCEPTUAL PROCESS DESIGN


Produce the preliminary Process design which will be passed to Conceptual Engineering Design and Detailed Process Design. It will also prepare a
feasibility and financial case for management.

1. Define Overall Requirement


1.1 Define End Requirements
Define the requirements the process must satisfy.
1.2 Identify Start conditions.
Identify the start conditions for the conceptual process
design, including:
The definition of the Battery Limits.
Identification of the status of any existing plant and the
performance characteristics of its processes.

2. Identify candidate processes


Identify potential processes for meeting the overall requirements.

3. Design Process
3.1 Define Unit Operations
Identify the constituent unit operations for a process.
3.2 Produce Energy / Mass Balance
Produce mass and energy balances for the overall process and for
each unit operation.
3.3 Produce Composition of Process Streams
Identify the material composition of each process stream.
3.4 Define Control Philosophy
Define the control philosophy for the process. For batch processes
include process timings.
3.5 Produce Process Flow Diagrams

Produce a Process Flow Diagram identifying all major items of


equipment and Process Streams.
4. Produce Feasibility/Financial Case
For each candidate process produce estimates of capital and operating
costs, operating manpower requirements, technical/financial risk
assessments and return on investment predictions.
5. Identify Safety / Regulatory Requirements
Identify all features of the process and plant which are potentially
hazardous and produce design philosophies to minimise/eliminate the
hazards.
Typical features considered:
Hazardous material handling
Effluent Treatment
Fire Protection
Pressure Relief/Containment
Emergency Shutdown
Safety Interlocking

Identify all features of the process and plant which are subject to
regulatory requirements and produce design philosophies to
meet those requirements.

PRODUCE CONCEPTUAL PROCESS DESIGN

PRODUCE
DETAILED
ENGINEERING
DESIGN

PRODUCE CONCEPTUAL ENGINEERING DESIGN


Determine
Engineering
Approach

Review
Process
Design
Determine
Status of
Existing
Plant
Define
Engineering
Design
Strategy
Obtain Codes &
Standards

Produce Conceptual
Mechanical

Produce Conceptual
Electrical

Produce Conceptual
Control &

Produce Conceptual
Safety

Define
Preliminary

Produce Conceptual
Civil / Structural

Engineering
Design

Engineering
Design

Instrumentation
Engineering Design

Engineering
Design

Plant
Layouts

Engineering
Design

Identify
Materials of
Construction

Identify
Materials of
Construction

Identify
Materials of
Construction

Produce Major
Equipment Design
Philosophy

Produce Major
Equipment Design
Philosophy

Produce Major
Equipment Design
Philosophy

Produce
Preliminary
Equipment & Line
Specifications

Produce
Preliminary
Equipment
Specifications

Produce
Preliminary
Equipment
Specifications

Define
Containment
Philosophy

Produce Cost
& Time Estimates

Produce Cost
& Time Estimates

Produce Control
System Architecture

Produce
Technical
Risks Assessment

Produce
Preliminary
Weight &
Volume Estimates

Produce
Preliminary
Weight & Volume
Estimates

Produce Cost
& Time Estimates

Define
Commissioning
Philosophy

Define
Commissioning
Philosophy

Produce Preliminary
Weight & Volume Estimates
Define Commissioning
Philosophy

Define
Safety
Philosophies

Review Site
Alternatives &
Conditions

Identify
Regulatory
Requirements

Produce
Preliminary
Layout
Drawings
Produce
Studies for
Cranage &
Handling

Produce Site Survey / Soil


Investigation
Define Civil / Structural
Philosophies
Identify Materials of
Construction
Produce Preliminary Building
or Module Layout Drawings
Produce Preliminary
Weight & Volume
Estimates
Define Construction
Philosophy
Define Building / Structural
Commissioning Philosophy

Preliminary Engineering Design


- Equipment Lists
- Preliminary Equipment
Specifications
- Materials of Construction
- Utility Requirements
- Preliminary Layout Drawings
- Weight & Volume Estimates
- Control Systems Architecture
- Technical Risks Assessment
Engineering Philosophies
- Design Philosophy
- Construction Philosophy
- Commissioning Philosophy
- Operations Philosophy
- Safety Philosophies
- Containment Philosophy
Availability Requirements
Cost & Time Estimates
Safety / Regulatory Requirements
Codes & Standards

P Harrow colact1 PISTEP 07/06/94

PRODUCE CONCEPTUAL ENGINEERING DESIGN


Produce the preliminary engineering philosophies to be used and the preliminary engineering design required for further detailed engineering
design.
1. Determine Engineering Approach
Determine the approach to be used in engineering of the process
definition. The following sub-activities are performed.
1.1 Review Process Design
Conduct a review of the process definition.
1.2 Determine Status of Existing Plant
Determine the status of any existing plant which is to be
modified..
1.3 Define Engineering Design Strategy
Define the strategy that will be used in the engineering
design of the plant.
1.4 Obtain Codes and Standards
Obtain the codes and standards either internal or external,
that will be used in the engineering design of the plant
2. Produce Conceptual Mechanical Engineering Design
Produce the preliminary mechanical engineering design.
2.1 Identify Materials of Construction
From the process definition, identify appropriate materials
for major process piping and equipment.
2.2 Produce Major Equipment Design Philosophy
From the process definition and the project plans, prepare an
outline statement of the rules and sequences for the design of
the major equipment.

2.3 Produce Preliminary Equipment, Line Lists


From the process definition, list the major process piping and
major equipment items for all disciplines.
2.4 Produce Preliminary Equipment Specifications
From the early process definition, generate preliminary
specifications for the major process piping and major
equipment items.
2.5 Produce Cost and Time Estimates
Produce project plans and budgets for capital and Design and
Engineering costs.
2.6 Produce Preliminary Weight and Volume Estimates
Add weight and volume estimates to the plant list for use in
conceptual plant layout and civil/structural design.
2.7 Define Commissioning Philosophy
Prepare an outline statement of the rules and sequences for
commissioning.
3. Produce Conceptual Electrical Engineering Design
Produce the preliminary electrical engineering design.
3.1 Identify Materials of Construction
From the process definition, identify appropriate materials
for major electrical cabling and equipment.
3.2 Produce Major Equipment Design Philosophy
Prepare an outline statement of the rules and sequences for
the design of the major electrical equipment.

3.3 Produce Preliminary Equipment Specifications


Generate preliminary specifications for the major electrical
equipment items.
3.4 Produce Cost and Time Estimates
Produce project plans and budgets for capital and Design and
Engineering costs.
3.5 Produce Preliminary Weight and Volume Estimates
Add weight and volume estimates to the plant list for use in
conceptual plant layout and civil/structural design.
3.6 Define Commissioning Philosophy
Prepare an outline statement of the rules and sequences for
commissioning.
4. Produce Conceptual Control & Instrumentation Engineering
Design
Produce the preliminary Conceptual Control and
Instrumentation engineering design.
4.1 Identify Materials of Construction
From the process definition, identify appropriate materials
for major process instrumentation and control equipment.
4.2 Produce Major Equipment Design Philosophy
Prepare an outline statement of the rules and sequences for
the design of the major equipment.
4.3 Produce Preliminary Equipment Specifications From
the process definition, generate preliminary
specifications for the major process instrumentation and
control equipment items.
4.4 Produce Control System Architecture
Produce the control system architecture to be used on the
plant.
4.5 Produce Cost and Time Estimates

Produce project plans and budgets for capital and Design and
Engineering costs.
4.6 Produce Preliminary Weight and Volume Estimates
Add weight and volume estimates to the plant list for use in
conceptual plant layout and civil/structural design.
4.7 Define Commissioning Philosophy
Prepare an outline statement of the rules and sequences for
commissioning.
5. Produce Conceptual Safety Engineering Design
Produce a conceptual safety design that will meet regulatory
requirements and conform to the codes and standards in force.
5.1 Define Safety Philosophies
From the regulatory requirements and the early process
definitions, outline the safety criteria appropriate to the type
of plant concerned.
5.2 Identify Regulatory Requirements
Identify the regulatory requirements that govern the siting,
construction and operation of the type of plant concerned.
5.3 Define Containment Philosophy
From the regulatory requirements and the early process
definitions, define the underlying rules for the plant
containment design.
5.4 Produce Technical Risks Assessment
From the developing conceptual design, perform and publish
initial hazard and operability studies.

6. Define Preliminary Plant Layouts

Study the alternative sites and produce a preliminary site layout


for the selected site.
6.1 Review Site Alternatives & Conditions
Review the alternative sites and the conditions applicable to
those sites.
6.2 Produce Preliminary Layout Drawings
From the early process definitions, plant list and volume
estimates, prepare initial plant layout proposals.
6.3 Produce Studies for Cranage and Handling
From the preliminary layout drawings and early process
definitions, prepare proposals for the cranage facilities and
other bulk-handling operations required in plant construction
and operation.
7. Produce Conceptual Civil/Structural Engineering Design
Produce the civil engineering work and structural engineering
required for the plant.
7.1 Produce Site Survey / Soil Investigation
Produce a site survey and investigate the soil for load bearing
and other properties.
7.2 Define Civil / Structural Philosophies
From the siting proposals, preliminary plant layouts and
regulatory requirements, prepare a statement of the design
rules and philosophies on which the civil/structural design is
based.
7.3 Identify Materials of Construction
From the siting proposals, preliminary plant layouts and
regulatory requirements, identify appropriate materials for
major aspects of the civil/ structural design.
7.4 Produce Preliminary Building or Module Layout
Drawings

From the siting proposals, preliminary plant layouts and


regulatory requirements, prepare preliminary civil and
structural layouts for the plant buildings or modules and the
site.
7.5 Produce Preliminary Weight and Volume Estimates From
the preliminary civil and structural layouts, prepare estimates
of weight and volumes for use in cost estimates and
foundation design.
7.6 Define Construction Philosophy
From the regulatory requirements and the preliminary
civil/structural layouts outline the rules and sequences on
which the civil/structural construction is to be based.
7.7 Define Building/Structural Commissioning Philosophy
From the developing civil/structural design and the project
plans, prepare an outline statement of the rules and sequences
for commissioning the civil/structural aspects of the plant.

PRODUCE CONCEPTUAL
PROCESS DESIGN
COMMISSION
PROCESS &
COMMISSION
PLANT

PRODUCE DETAILED PROCESS DESIGN


Produce
Piping &
Instrumentation
Diagrams

Produce
Functional
Specification
for Equipment

Produce
Control
Requirements
Specification

Identify
Control
Requirements

Define Relief &


Blowdown Philosophy

Identify Trip
Requirements

Define Protective
System (Including Fire)
Philosophy

Produce
Control
Requirements
Specification

PRODUCE
DETAILED
ENGINEERING
DESIGN

Satisfy Safety
Requirements

Define Hazardous Areas

Produce
Plant
Operating
Procedures

Performance Requirements
Operating Procedures
Operating Conditions
Alarm / Trip Settings
Safety and Environment
Case

Produce Safety &


Environment Case

Detailed Process Design


- Piping & Instrumentation Diagrams
- Functional Specifications
- Control Specifications
- Alarm / Trip Settings
- Utility Systems Requirements
- Design Philosophies
Availability Requirements
Safety Systems Specifications
Operating Procedures
Codes & Standards

P Harrow colact1 PISTEP 26/04/94

PRODUCE DETAILED PROCESS DESIGN


Produce the detailed process design which provides the specifications, requirements, codes and standards, design and operation philosophies
required for the Detailed Engineering Design and Commissioning.
1. Produce Piping & Instrumentation Diagrams
Produce schematic drawings detailing equipment, instrument
and piping connectivity.
2. Produce Functional Specification for Equipment
Produce a specification for the functional requirements for all
equipment including process design conditions, material
specifications, insulation requirements and tracing requirements.
3. Produce Control Requirements Specifications
Produce the requirements specification for the plant control
systems.
3.1 Identify Control Requirements
Identify the specific control requirements for the complete
plant and for each unit operation.
3.2 Identify Trip Requirements
Identify the alarm, interlock and shutdown requirements for
the complete plant and for each unit operation.
3.3 Produce Control Requirements Specification
Produce a specification detailing the control requirements for
the plant, the alarm interlock and shutdown requirements.
4. Satisfy Safety Requirements
Produce philosophies to meet the safety requirements of the
owners of the plant and regulatory authorities.

4.1 Define Relief & Blowdown Philosophy


Define the relief and blowdown philosophy to be used in the
plant design that will ensure safe and reliable operation of the
plant.
4.2 Define Protective System (including Fire) Philosophy
Define the protective systems philosophy for the plant
including normal and specialised fire fighting requirements.
4.3 Define Hazardous Areas
Define the hazardous areas of the plant which may arise due
to the use of toxic substances, radiation, inflammable fluids
or gases.
4.4 Produce Safety & Environment Case
Produce safety and environmental studies that may be
required by regulatory bodies or planning (Zoning)
authorities.
5. Produce Plant Operating Procedures
Produce any procedures that may be required for
Commissioning or Operation of the plant.

PRODUCE DETAILED
PROCESS DESIGN
PRODUCE DETAILED ENGINEERING DESIGN

PRODUCE
CONCEPTUAL
ENGINEERING
DESIGN

Produce Detailed
Mechanical
Engineering
Design
Produce Piping &
Mechanical
Equipment Design
Produce Equipment
Handling Systems
Design
Produce Detailed
Mechanical
Equipment
Specifications
Define Mechanical
Equipment Spares
Requirements
Produce Mechanical
Maintenance
Procedures

Produce Detailed
Electrical
Engineering
Design

Produce Detailed
Control &
Instrumentation
Engineering Design

Review & Detail


Plant / Building
Electrical
Requirements

Review & Detail


Instrumentation
Plant / Building
Requirements

Produce Earthing
Requirements
(Static,
Lightning, Power)

Produce Clean
Earthing
Requirements

Produce
Communication
System Design

Produce
Measurement
Instrumentation
Specification

Produce Electrical
Equipment
Specifications

Produce Actuator
Specifications

Produce Electrical
Cable Runs Design

Produce Control
Systems
Specifications

Produce Power
Distribution
Systems
Design
Produce Electrical
Environment
Control
Requirements
Define Electrical
Equipment Spares
Requirements
Produce Electrical
Maintenance
Procedures

Produce Detailed
Layout &
Construction
Design

Define Signal
Transmission
Pathways

Produce Site
Layout
Produce 3D
Plant Model
Coordinate
Interfaces
Between Design
Areas
Produce Site
Construction &
Installation
Methodology
Define Test &
Pre-Commissioning
Requirements

Produce Building
& Plant
Services Design

Produce
Domestic
Water,
Sewage &
Storm Water
Design
Produce
Environmental
Control
Systems
Design
Produce
Lighting &
Small Power
Design
Produce Fire
Protection
Systems
Design

Produce Environmental
Control Requirements
for Instrumentation
Define Instrumentation
& Control Equipment
Spares Requirements
Produce Instrumentation
& Control Maintenance
Procedures

Produce Detailed
Civil / Structural
Engineering
Design

Produce Detailed
Safety
Engineering
Assessment

Produce Site Survey /


Soil Investigation

CONSTRUCT &
PRE-COMMISSION
PLANT

Produce Room / Module


Specifications
Produce Civil
Construction
Drawings
Design Containment
Systems
Design Process
Effluent Drainage
Systems
Design Foundation
Structures
Produce Painting &
Surface Finish
Specifications
Produce Weight
Schedules
Produce Bill Of
Quantities

Detailed Engineering Design


- Detailed Equipment Specification
- Piping & Instrumentation Diagrams
- 2D Schematics
- 3D Model
- Construction Drawings
Equipment Procedures
- Installation Procedures
- Commissioning Procedures
- Operating Procedures
- Maintenance Procedures
Vendor Drawings
Spares Lists

Equipment & Materials Requirements


and Specifications
Required on Site Dates

PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES

P Harrow colact1 PISTEP 26/04/94

PRODUCE DETAILED ENGINEERING DESIGN


Produce the Detailed Engineering Design for the plant including all specifications, drawings, construction and commissioning plans, 3D
models, materials takeoff and spares lists.
1. Produce Detailed Mechanical Engineering Design
Produce the detailed engineering design for the mechanical
equipment and piping for the plant.
1.1 Produce Mechanical & Piping Equipment Design
From the equipment data sheets, piping and instrumentation
diagrams and plant layouts, produce detailed procurement
specifications for mechanical equipment items and
fabrication specifications for piping.
1.2 Produce Equipment Handling System Design
From the process facility data and mechanical handling
equipment specifications, produce designs for plant
mechanical handling systems.
1.3 Produce Detailed Mechanical Equipment Specifications
Produce specifications for all items of mechanical equipment
on the plant.
1.4 Define Mechanical Equipment Spares Requirement
Define the spares requirement for all items of mechanical
equipment on the plant.
1.5 Produce Maintenance Procedures
Produce the procedures to effectively maintain all items of
mechanical equipment on the plant.
2. Produce Detailed Electrical Engineering Design
Produce the detailed engineering design for the electrical
equipment and cabling for the plant.

2.1 Review & Detail Plant / Building Electrical Requirements


Review the electrical requirements received from Detailed
Process Design and Conceptual Engineering Design and
refine to give a detailed list of requirements.
2.2 Produce Earthing requirements (Static, Lightning,
Power)
Produce the requirements for protection of the plant from the
build-up of static electricity, lightning protection and
earthing of electrical power systems equipment.
2.3 Produce Communication System Design
Produce the design of any communication systems required
for the operation of the plant.
2.4 Produce Electrical Equipment Specifications
Produce specifications for all items of electrical equipment
on the plant.
2.5 Produce Electrical Cable Runs Design
Produce the electrical cable runs design for the plant.
2.6 Produce Power Distribution Systems Design
Produce the power distribution systems design.
2.7 Produce Electrical Environment Control Requirements
Produce the requirements for environmental control of
electrical equipment on the plant.
2.8 Define Electrical Equipment Spares Requirement
Define the spares requirement for all items of electrical
equipment on the plant.

2.9 Produce Maintenance Procedures


Produce the procedures to effectively maintain all items of
electrical equipment on the plant.
3. Produce Detailed Control & Instrumentation Engineering
Design
Produce the detailed engineering design for the control and
instrumentation equipment and cabling for the plant.
3.1 Review & Detail Instrumentation Plant / Building
Requirements
Review the instrumentation requirements received from
Detailed Process Design and Conceptual Engineering Design
and refine to give a detailed list of requirements.
3.2 Produce Clean Earthing requirements
Produce the requirements for clean earths for the
instrumentation system.
3.3 Produce Measurement Instrumentation Specification
Produce the specification for instrumentation used to
measure process conditions in the operation of the plant.
3.4 Produce Actuator Specifications
Produce specifications for all actuators on the plant.
3.5 Produce Control Systems Specification
Produce the control systems specification for the plant.
3.6 Define Signal Transmission Pathways
Define the signal transmission pathways required by the
instrumentation system.
3.7 Produce Environmental Control Requirements for
Instrumentation
Produce the requirements for environmental control of
instrumentation equipment on the plant.

3.8 Define Instrumentation Equipment Spares Requirement


Define the spares requirement for all items of instrumentation
equipment on the plant.
3.9 Produce Maintenance Procedures
Produce the procedures to effectively maintain all items of
instrumentation equipment on the plant.
4. Produce Layout & Construction Design
From the Equipment design produce the layout and construction
design
4.1 Produce Site Layout Drawing
From the preliminary civil/structural layouts and the detailed
plant layouts, prepare the final site layout drawing.
4.2 Produce 3D Model
From the piping and instrumentation diagrams and
preliminary plant layouts, produce the 3D plant model
incorporating plant structure, piping, ventilation, cabling
reservations and plant.
4.3 Co-ordinate Interfaces Between Design Areas
Co-ordinate the interfaces between design areas from
different design sources, to ensure compatibility of all
aspects of design across the boundaries.
4.4 Produce Site Construction & Installation Methodology
From the 3D layouts, the floor plans/elevations and the
developing detailed plant design, produce all layout and
construction detail drawings that are necessary to support
plant construction activities.
4.5 Define Test & Pre-Commissioning Requirements
Define the test and pre-commissioning requirements for the
plant.

5. Produce Plant/Building Services Design


From the piping and instrumentation diagrams and preliminary
plant layouts, produce detailed piping, ventilation and plant
layouts.
5.1 Produce Domestic Sewerage and Storm Water Design
From the detailed plant layouts and the site layout, produce
the detail drawings to define the domestic sewerage and
storm water management systems.
5.2 Produce Environmental Control Systems Design
From the room data sheets, equipment data sheets and the
detailed plant layouts, produce detailed procurement
specifications for air-conditioning and other environmental
control systems.
5.3 Produce Lighting and Small Power Design
From the room data sheets and the detailed plant layouts,
produce the layouts and procurement specifications to
support the design and installation of the lighting and small
power systems.
5.4 Produce Fire Protection Systems Design
From the detailed plant layouts and the regulatory
requirements, produce the layouts and procurement
specifications to support the design and installation of the fire
protection systems.
6. Produce Detailed Civil/Structural Engineering Design
From the detailed plant layouts produce the detailed civil and
structural designs required for the plant.

6.1 Produce Site Survey / Soil Investigation

From the preliminary plant siting studies, perform physical


surveys of ground contour, groundwater flow and underlying
geology to support the choice of site.
6.2 Produce Room/Module Specifications
From the process facility data, detailed plant layouts and
equipment data sheets, produce the room or module
specifications.
6.3 Produce Civil Construction Drawings
Produce the drawings for any civil construction work
required.
6.4 Design Containment Systems
Implement the containment systems design in civil and
structural design features where appropriate.
6.5 Design Process Effluent Drainage Systems
From the detailed process flow diagrams and the detailed
plant layouts, design the necessary collection and storage
facilities and pipework to allow the removal of process
effluents.
6.6 Design Foundation Structures
From the preliminary civil/structural weight estimates, the
site survey data and seismic design criteria, produce the
detailed plant foundations designs.
6.7 Produce Painting and Surface Finish Specification
Produce the painting and surface finish specification for the
plant and ancillary buildings.
6.8 Produce Weight Schedules
Produce weight schedules for civil / structural items where
appropriate.
6.9 Produce Bill of Quantities

From the detailed civil/structural layouts, derive the Bills of


Quantities needed to enable plant construction.
7. Produce Detailed Safety Engineering Assessment
Produce a detailed safety engineering assessment for the plant.

Equipment & Materials Catalogues


- Equipment & Materials Specifications
- Equipment & Material Availability & Prices
- Spares Lists
Delivery Dates
Vendor Drawings
Certification
Equipment Procedures
- Installation Procedures
- Commissioning Procedures
- Operating Procedures
- Maintenance Procedures
Inspection Results
Shipping Details

Equipment & Materials Catalogues


- Equipment & Materials Specifications
- Equipment & Material Availability & Prices
- Spares Lists
Delivery Dates
Vendor Drawings
Certification
Equipment Procedures
- Installation Procedures
- Commissioning Procedures
- Operating Procedures
- Maintenance Procedures

Equipment & Materials Catalogues


- Equipment & Materials Specifications
- Equipment Availability & Prices
- Spares Lists
Delivery Dates
Vendor Drawings
Certification
Equipment Procedures
- Installation Procedures
- Commissioning Procedures
- Operating Procedures
- Maintenance Procedures
Invoices

SUPPLIERS &
FABRICATORS

Equipment & Materials Requirements &


Specifications
Required on Site Dates
Inspection Results
Shipping Details
Payment Details

PRODUCE
DETAILED
ENGINEERING
DESIGN

CONSTRUCT &
PRE-COMMISSION
PLANT

MAINTAIN
EQUIPMENT

PROCURE & CONTROL EQUIPMENT MATERIALS & SERVICES


Maintain
Suppliers
List

Issue
Enquiries

Evaluate

Maintain List
Of Preferred
Suppliers

Compile
Bidders
List

Condition
Bids

Maintain
Relationship
with Suppliers

Produce
Enquiry
Documents
Compile
Conditions
of Contract

Bids

Select
Supplier

Commit
Purchase

Produce
Purchase
Orders
Confirm
Final
Conditions
of Contract

Expedite
Manufacture

Expedite
Progress
Authorize
Stage
Payments
Respond to
Technical
Queries

Inspect

Inspect
Equipment,
Materials
& Services
Respond to
Concession
Requests

Release for
Shipment
From Supplier

Ship Goods
From
Supplier

Control
& Issue
Equipment
& Materials

Issue
Release Note

Pack
Goods

Produce Material
Stock Strategy

Close out
Purchase
Order

Make
Shipping
Arrangements

Unload
Goods

Authorize
Final
Payments

Ship Goods

Store Goods
Control &
Monitor
Stock
Issue & Transport
Goods To Required
Location

P Harrow colact1 PISTEP 10/06/94

PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES


Make enquiries, place purchase orders, inspect and expedite progress, ship goods and control stock of equipment, and materials.
1. Maintain Suppliers List
Keep up to date records of potential suppliers of equipment,
materials or services, including information on prequalifications, range of goods and services available etc.
1.1 Maintain List of Preferred Suppliers
Issue and record pre-qualification questionnaires for possible
suppliers of equipment, materials and services, including
information on range of goods and services offered.
1.2 Maintain Relationship With Supplier
Maintain the relationship and keep up to date with product
and technological advances etc.
2. Issue Enquiries
Issue the full set of enquiry documents to suppliers listed on the
bidders list.
2.1 Compile Bidders List
From the maintained suppliers lists, list those vendors who
have suitable experience and pre qualifications to tender for
the required goods and services.
2.2 Produce Enquiry Documents
Compile all the enquiry documentation, from the equipment,
materials and service requirements.
2.3 Compile Conditions Of Contract
Determine the contractual conditions that will apply to the
eventual purchase order. These are part of the issued enquiry.

3. Evaluate Bids
Review all the tender documents received from suppliers and
make the recommendations as to where to place the purchase
order.
3.1 Condition Bids
Resolve the non conformances within the tender documents
from suppliers
3.2 Select Supplier
Choose the successful supplier from the tenders received
4. Commit Purchase
Issue purchase order to the successful supplier.
4.1 Produce Purchase Orders
Compile all the purchase documentation, from the
equipment, materials and service requirements.
4.2 Compile Final Conditions Of Contract
Determine the contractual conditions of contract that will
apply to the purchase order from the condition bid stage.
These are part of the purchase order.
5. Expedite Manufacture
Review suppliers performance and contract progression against
promised delivery and required on site dates.
5.1 Expedite Progress
Review supplier progress, produce and issue a progress
report to aid the detailed design and construction activities

5.2 Authorise Stage Payments


Check that stage payments are due. Authorise and make
stage payments upon the conditions of contract being met
that allow stage payments to be made.
5.3 Respond To Technical Queries
Resolve any technical queries that occur during the
manufacturing period.
6. Inspect
Inspect the equipment, materials and services for compliance to
specification
6.1 Inspect Equipment, Materials & Services
Inspect the equipment, materials or services being provided
noting problem areas that either need reworking or
concessions granting.
6.2 Respond To Concession Requests
Organise and respond to any request for concessions, liaising
with the detailed engineering design.
7. Release for Shipment from Supplier
Authorise the shipment of equipment or materials at the end of
the fabrication and manufacture contract
7.1 Issue Release Note
After the last inspection, of the finished items or work, issue
a release note that states that the items or work are to
specification and are satisfactory.
7.2 Close Out Purchase Order
Check and confirm that all contractual requirements have
been met by the supplier.
7.3 Authorise Final Payments

Check that final payments are due. Authorise and make


payments upon the conditions of contract being met that
allow payments to be made
8. Ship Goods from Supplier
Arrange and transport the goods from the suppliers to the site or
facility.
8.1 Pack Goods
Pack the equipment or materials suitably, and make ready for
transportation from the suppliers.
8.2 Make Shipping Arrangements
Arrange transportation for equipment and materials
8.3 Ship Goods
Ship goods to site or holding area.
9. Control & Issue Equipment & Materials
Control and issue equipment and materials to construction or
maintenance.
9.1 Produce Material Stock Strategy
Produce a strategy for holding stock required for construction
and maintenance.
9.2 Unload Goods
Unload the goods from their transportation for storage.
9.3 Store Goods
Provide storage of equipment and materials
9.4 Control & Monitor Stock
Monitor stock levels to ensure equipment and materials are
available when required and raise requests to purchase more
stock if necessary.
9.5 Issue Goods and Transport Goods to Required Location

When details of equipment and materials requirements are


received from maintain plant check if equipment or materials
are in stock. If so issue the equipment or materials to
maintain plant.

COMMISSION PROCESS
& HANDOVER PLANT
As Built Drawings
Equipment Commissioning Procedures
Equipment Operating Procedures
Inspection & Testing Records
Handover Certification
P

MAINTAIN
EQUIPMENT

ENGINEERING
DESIGN

CONSTRUCT & PRE-COMMISSION PLANT


Produce
Construction
Plans

Produce
Contract
Plan
Produce
Construction
Plan

Establish
Construction
Services

Erect
Plant

Produce
As-Built
Surveys

Pre-Commission

Perform
Civil /
Structural
Construction

Perform
Conformance
Checks

Clean Plant for


Testing and
Commissioning

Erect Major
Plant Items

Produce AsBuilt
Specifications
& Drawings

Prepare Equipment
for Commissioning

Construct
Piping
Install Electrical
& Instrumentation
Systems

Identify
Unfinished
Work

Perform
Pre-commissioning
Tests
Perform Baseline
Inspection

Handover To
Process
Commissioning

As Built Drawings
As Built Equipment Specifications
Spares Lists
Installation Procedures
Maintenance Procedures
Inspection Results
Unfinished Work Details

Complete Special
Finishes, Thermal
Insulation & Painting

PROCURE & CONTROL


EQUIPMENT, MATERIALS
& SERVICES

P Harrow colact1 PISTEP 26/04/94

CONSTRUCT and PRE-COMMISSION PLANT


Construct the plant as defined by the detail design specifications and plan to meet the needs of the commissioning team. Construction
includes verification that the design has been satisfied and that the resulting plant is acceptable to the commissioning team.
1. Produce Construction Plans
Produce plans used in the construction of the plant.
1.1 Produce Contract Plan
The activity of producing a contract plan which details the
organisations responsible for implementing the work
packages of the construction plan.
1.2 Produce Construction Plan
Produce a construction plan which identifies all construction
work packages, their time and resource requirements and
dependencies.
2. Establish Construction Services
The temporary construction services required for the
construction of the plant.( e.g. temporary office, workshop,
carpark etc. ).
3. Erect Plant
Construct the plant as defined by the detailed design
specifications and verification that the construction work
satisfies the design.
3.1 Civil / Structural Construction
Perform the civil and structural work as defined by the civil
and structural detail design specifications, and verification
that the design has been satisfied.
(e.g. establishment of foundations, drainage systems, effluent
containment systems, buildings, pipe bridges etc).

3.2 Erect Major Plant Items


Locate major plant items on foundations or structures as
defined by the detail design specifications, and verify that the
design has been satisfied.
Major plant items are considered to be fabricated elsewhere
and supplied to construction essentially complete. In some
cases assembly of sub units may be required during
construction e.g. a large column may be transported to site in
3 pieces and assembled on site. The verification activity
would typically be inspection of the erected major plant item,
pressure testing etc.
3.3 Construct Piping
Install pipework as defined by the detailed piping design
specifications, and verify that the design has been satisfied.
The verification activity would typically be inspection of the
piping, pressure testing etc.
3.4 Install Electrical and Instrumentation Systems
Install electrical and instrumentation equipment as defined by
the detailed electrical and instrumentation design
specifications, and verify that the design has been satisfied.
The verification activity would typically be electrical and
instrument loop testing, off line testing of the trip system and
control system etc.

3.5 Complete Special Finishes, Linings, Thermal Insulation


And Painting
Implement finishes, linings, thermal insulation and painting
as defined by the detailed design specifications, and verify
that the design has been satisfied.
4. Produce As Built Surveys
Survey the finished construction work in order to identify non
conformance with the detail design specifications, and update
the design specifications with the design changes implemented
during construction.
4.1 Perform Conformance Checks
Survey the finished construction work in order to identify
non conformance with the detail design specifications that
need resolution.
Reference may be made to the verification records for the
construction activities and inspection data for bought in
major plant items, e.g. records of pressure testing vessels etc.
4.2 Produce As Built Specifications & Drawings
Update the detailed design specifications and drawings with
the approved design changes implemented during
construction.
4.3 Identify Unfinished Work
Identify any unfinished work and allocate responsibility for
its completion.
5. Pre Commission
Prepare the plant for commissioning.
5.1 Clean Plant for Testing and Commissioning
Clean and flush the plant in preparation for testing and
commissioning.
5.2 Prepare Equipment for Commissioning

Prepare the equipment for commissioning. This would


include packing the vessels with non feedstock material,
including flow dispersers, catalyst etc.
5.3 Perform Precommissioning Tests
Test the individual items of equipment before inert or process
fluids are introduced, e.g. testing pump motors etc.
5.4 Perform Baseline Inspection
Perform the baseline inspection of e.g. pressure systems
6. Handover to Process Commissioning
Transfer responsibility for the plant from the construction team to
the commissioning team, documented by a Handover Certificate.

PRODUCE
DETAILED
PROCESS
DESIGN

OPERATE
PLANT

COMMISSION PROCESS & HANDOVER PLANT


Produce
Commissioning
Plan

Train
Commissioning
Personnel

Commission
Plant

Perform Trip
Tests
Perform Cold
Commissioning
Perform Hot
Commissioning
Tune Control
Systems

Perform
Acceptance
Testing

Identify Plant
Performance
Envelope
Compare
Performance to
Specification
Identify Corrective
Actions &
Responsibility

Handover
Plant For
Operation

Update Operating
Procedures
Finalize
Agreement
With Regulatory
Bodies

As Built Drawings
Operating Procedures
Acceptance Test results
Handover Certificate

Perform Plant
Handover

CONSTRUCT &
PRE-COMMISSION
PLANT
P Harrow colact1 PISTEP 26/04/94

COMMISSION PROCESS & HANDOVER PLANT


Prove operation of all plant systems as defined by the detailed design specifications such that the plant can be accepted for operation to
manufacture product.
Commissioning typically consists of a number of stages progressing from activities using either non or inert process materials to the use of
production process materials.
1. Produce Commissioning Plan
Produce a commissioning plan which identifies all
commissioning activities, their time and resource requirements
and dependencies.
2. Train Commissioning Personnel
Train personnel to commission the plant.
3. Commission Plant
Prove operation of the plant as defined by the detail design
specifications by the introduction of process materials into the
plant and operating the plant to prove the process transforms
feedstocks to products.
3.1 Perform Trip Tests
Prove operation of the plant safety trip system as defined by
the detail design specifications.
The trip test would use as far as practicable real process
conditions to cause trip detection with use of simulation via
instrument signal injection only on limited cases. For
example level trips would be tested by introducing a liquid
into the vessel.

3.2 Perform Cold Commissioning


Prove operation of the plant as defined by the detail design
specifications by the introduction of inert feedstock materials
into the plant and performing the unit operations designed to
effect transformation into product or products.
3.3 Perform Hot Commissioning
Prove operation of the plant as defined by the detail design
specifications by the introduction of production feedstock
materials into the plant and operating the plant to prove the
process transforms feedstocks to products.
3.4 Tune Control Systems
Tune the control loops within the control system for the
plant.
4. Perform Acceptance Testing
Test the plant under operating conditions to ensure that it
conforms to the design specification and obtain the performance
envelope for the plant.
4.1 Identify Plant Performance Envelope
Operate the plant under various conditions to determine the
operating range for the plant.
4.2 Compare Performance to Specification
Compare operation with the detail process design
specifications.

4.3 Identify Corrective Actions & Responsibility


Identify any corrective actions required to make the plant
perform to specification and the allocate responsibility for
those corrective actions.
5. Handover Plant for Operation
Transfer responsibility for the plant from the commissioning
team to the operating team, documented by a handover
certificate.
5.1 Update Operating Procedures
Update the operating procedures to incorporate changes that
may have occurred during construction and commissioning.
5.2 Finalise Agreement with Regulatory Bodies
Obtain the final agreement with the regulatory bodies that all
relevant regulations have been met and that the plant may be
put into operation.
5.3 Perform Plant Handover
Produce the handover certificate and hand the plant over to
the operating staff for operations.

COMMISSION PROCESS
& HANDOVER PLANT

OPERATE PLANT

DECOMMISSION
PLANT

Ensure
Safe Plant
Operation

Plan &
Schedule
Plant
Operation

Obtain Operating
Procedures

Define
Operating Modes

Obtain Operating
Schematics

Plan Plant
Operations

Define Safety
And Security
Procedures

Schedule Plant
Operations

Operation
Of Plant

Configure Plant
Start-up Plant
Monitor Plant
Performance
Optimize Plant
Performance

Obtain Certificate
to Operate

Account for Plant


Performance

Maintain Safety
Case

Shutdown &
Clean Out Plant

Train Operating
Personnel

Dispose of
Inventory

Request and
Approve Work
on Plant

Identify
Requirement
for Engineering
Work

Plant Status
Ground Drains Status
Safety Case
As Built & As Modified Drawings

Request
Engineering Work
Approve Work
Permits
Ensure Safe
Working
Conditions
Accept
Engineering
Work

Engineering Work Requests


Working Conditions Requirements
Engineering Work Permits
Acceptance of Engineering Work

MAINTAIN
EQUIPMENT

P Harrow colact1 PISTEP 26/04/94

31

OPERATE PLANT
Operate plant safely, efficiently, and according to plan.
1. Ensure Safe Plant Operation
Take those steps necessary to ensure that the plant can be
operated in a safe and proper manner.
1.1 Obtain Operating Procedures
Acquire Operating Procedures from the Process Design team.
1.2 Obtain Operating Schematics
Acquire Operating Schematics from the Process Design
team.
1.3 Define Safety and Security Procedures
Define the procedures that will ensure that the plant is
operated in a safe manner at all times, and that the security of
the plant is not breached at any time.
1.4 Obtain Certificate to Operate
Acquire the certificate to operate the plant and ensure that it
properly reflects the use of the plant.
1.5 Maintain Safety Case
Ensure that the safety case for the plant properly reflects the
state and operation of the plant, and to revise the safety case
when this is appropriate.
1.6 Train Operating Personnel
Train the personnel in the procedures that will ensure that the
plant is operated in a safe and efficient manner at all times,
and that the security of the plant is not breached at any time.

2.1 Define Operating Modes


Identify and define the standard ways in which the plant
should operate so that plans can be based on these standard
operating modes.
2.2 Plan Plant Operations
Plan for the longer term and in restricted detail the way the
plant should operate.
2.3 Schedule Plant Operations
Plan in detail the operation of the plant in the immediate
future.
3. Operation of Plant
Operate the plant to produce products in a safe, efficient and
effective manner.
3.1 Configure Plant
Line-up the plant choosing which circuits to use from the
available options.
3.2 Start-up Plant
Prepare the plant for the introduction of feed. Introduce the
feed, and bring the plant up to normal operating conditions.
3.3 Monitor Plant Performance
Measure process conditions, and summarise as appropriate
for reporting purposes.
3.4 Optimise Plant Operations

2. Plan and Schedule Plant Operations


Plan the way that the plant will operate in future periods.
32

Check plant performance conforms to target performance,


and take corrective action where necessary.
3.5 Account for Plant Performance
Create formal record of plant performance for accounting
purposes.
3.6 Shut-down & Clean Out plant
Reduce operating conditions and feedstock flowrates in such
a way as to safely bring the plant out of operation. Clean out
plant to remove any remaining feedstocks.
3.7 Dispose of Inventory
Remove feedstocks and other reagents from the plant.
4. Request and approve Work on Plant
Request maintenance. Approve proposed maintenance work.
Make sure work is carried out safely, and sign-off completed
work.
4.1 Identify Requirement for Engineering Work
Identify the need for engineering work when equipment does
not work or fails to operate as expected.
4.2 Request Engineering Work
Define priority of maintenance requirements and request that
they are carried out.
4.3 Approve Work Permits
Ensure that the way work is proposed to be carried out is
safe.
4.4 Ensure Safe Working Conditions
Ensure that conditions are safe whilst work is carried out, e.g.
no flammable materials in area if hot work is being carried
out.
4.5 Accept Engineering Work

Check that work has been satisfactorily completed before


making plant available for operation.

34

OPERATE
PLANT
Inspection Requirements Work
Permit Requests Notification of
Work Completion

MAINTAIN EQUIPMENT
CONSTRUCT &
PRE-COMMISSION
PLANT

Define
Maintenance
Approach

Obtain Plant Availability


Requirements
Obtain Equipment
Records
Obtain Plant &
Equipment Drawings
Obtain & Develop
Maintenance
Procedures
Define Preventative,
Breakdown, Shutdown
Maintenance Strategy
Obtain & Develop Spares
Strategy
Obtain Hazardous
Materials Data
Train Maintenance &
Inspection Staff

Prepare For
Maintenance
Or
Inspection

Plan Actual
Maintenance
Or
Inspection

Maintain
Or
Inspect
Equipment

Respond to Maintenance
Request

Obtain Equipment
Records

Prepare Site
for Work

Identify Routine
Maintenance Requirement

Obtain Plant &


Equipment Drawings

Perform
Maintenance
or Inspection

Identify Inspection
Requirements

Obtain Maintenance
Procedures

Obtain Equipment Records

Obtain Resources

Obtain Plant & Equipment


Drawings

Obtain Work Permits


Obtain Inspection
Reports

Obtain Maintenance
Procedures

DEMOLISH PLANT
& RESTORE SITE

State of Equipment
Value of Equipment
Equipment Records

Record
Resources
Consumed
Update
Equipment
Records

Obtain Plant Availiability


Requirements
Identify Resource
Requirements
Schedule Maintenance
& Inspection

Materials & Equipment Requirements & Specifications


Required on Site Dates

PROCURE & CONTROL


EQUIPMENT, MATERIALS
& SERVICES
P Harrow colact1 PISTEP 10/06/94

35

36

MAINTAIN EQUIPMENT
Maintain plant and equipment in a safe manner to ensure plant operability.
1. Define Maintenance Approach
Define the approach to the task of maintaining plant and
equipment.
1.1 Obtain Plant Availability Requirements
Obtain the plant availability requirements which the
maintenance must achieve.
1.2 Equipment Records
Obtain the records for each item of equipment in the plant.
1.3 Obtain Plant and Equipment Drawings
Obtain the drawings for the plant and each item of equipment
in the plant.
1.4 Obtain and Develop Maintenance Procedures
Procedures provide information for performing tasks relating
to routine, preventative, inspection and corrective
maintenance activities. The procedures will have to be
developed as the plant is modified or the need for new
procedures arise.
1.5 Define Preventative, Breakdown, Shutdown Maintenance
Strategy
Define the strategy to be followed for preventative
maintenance and maintenance required as the result of
breakdown or shutdown.
1.6 Obtain and Develop Spares Strategy
Obtain the spares strategy developed during the Detailed
Engineering Design and develop this to meet the needs of the
plant and equipment.

1.7 Obtain Hazardous Materials Data


Obtain the data relating to the storage, handling and disposal
of hazardous materials issued by Regulatory Bodies, or
others.
1.8 Train Maintenance & Inspection Staff
Train staff in inspection and maintenance procedures so that
the equipment is inspected and maintained in a safe and
timely manner.
2. Plan Actual Maintenance or Inspection
Plan the sequence of operations required to perform inspection
or maintenance of equipment.
2.1 Respond to maintenance Request
Identify the manpower, materials, special resources, estimate
costs and Work Permits required to meet the maintenance
request.
2.2 Identify Routine Maintenance Requirement
Identify requirements for routine maintenance for equipment
based on the maintenance approach and procedures for the
equipment.
2.3 Identify Inspection Requirements
Identify inspection requirements for equipment based on the
maintenance approach and procedures for the equipment.
2.4 Obtain Equipment Records
Obtain the records for each item of equipment to be
maintained or inspected.

37

2.5 Obtain Plant and Equipment Drawings


Obtain the drawings for the plant and each item of equipment
in the plant to be maintained.
2.6 Obtain Maintenance Procedures
Obtain the procedures which provide information for
performing tasks relating to routine, preventative, inspection
and corrective maintenance activities.
2.7 Obtain Plant Availability Requirements
Obtain the plant availability requirements which the
maintenance must achieve.
2.8 Identify Resource Requirements
Identify the resources in personnel, spares and special tools
required to perform the maintenance or inspection.
2.9 Schedule Maintenance & Inspection
Schedule the maintenance or inspection required.
3. Prepare for Maintenance or Inspection
Prepare to carry out the required maintenance or inspection.
3.1 Obtain Equipment Records
Obtain the records for each item of equipment to be
maintained or inspected.
3.2 Obtain Plant and Equipment Drawings
Obtain the drawings for the plant and each item of equipment
to be maintained.
3.3 Obtain Maintenance Procedures
Obtain the procedures which provide information for
performing the maintenance or inspection.
3.4 Obtain Resources
Obtain the resources in personnel, spares and special tools
required to perform the maintenance or inspection.
3.5 Obtain Work Permit

Obtain authorisation to allow work to be executed and the


conditions that must be fulfilled to perform the work safely.
3.6 Obtain Inspection Report
The inspection report records the results of the last inspection
of an equipment item with details of conditions inspected e.g.
Test Pressure.
4. Maintain or Inspect Equipment
Prepare the site and perform the required maintenance or
inspection.
4.1 Prepare the site for work
Perform any preparatory work on the site before undertaking
maintenance or inspection.
4.2 Perform Maintenance or Inspection
Perform the required maintenance or inspection.
4.3 Record Resources Consumed
Provide a record of resources in labour and spares consumed
in performing the maintenance activities.
4.4 Update Equipment Records
Update the records of activities and work completed on the
equipment.

DECOMMISSION PLANT
O

PLANT

Define
Decommissioning
Requirements

Identify Current
Status
Define Final
Status

Produce
Decommissioning
& Restoration
Plan

Perform
Preparatory
Works

Clean &
Mothball
Plant

Isolate Services

Clean Plant

Provide
Temporary Services

Mothball Plant

Provide
Decommissioning
Equipment

Archive Plant
Records
Determine
Inspection
Requirements
Finalize
Regulatory
Approvals

Plant Status
Plant Records
Inspection Requirements
Regulatory Approvals

DEMOLISH PLANT
& RESTORE SITE

P Harrow colact1 PISTEP 24/04/94

DECOMMISSION PLANT
Take a plant out of operating service, isolate all feedstock and services, remove all process materials from the plant, and establish
maintenance conditions such that the plant could be returned to operating service.
1. Define Decommissioning Requirements
Identify the current plant status and define the required mothball
plant status.
1.1 Identify Current Status
Identify the current plant status.
1.2 Define Final Status
Define the final plant status.
2. Produce Decommissioning & Restoration Plan Produce a
decommissioning plan which identifies all decommissioning
activities, restoration activities and their time and resource
requirements and dependencies.
3. Perform Preparatory Works
Undertake preparatory works required before the plant may be
cleaned and mothballed.
3.1 Isolate Services
Isolate power and other services from the plant.
The isolation would typically be electrical power, instrument
and process air, steam, cooling water etc.
3.2 Provide Temporary Services
Provide temporary services required during the cleaning and
mothballing of the plant.
3.3 Provide Decommissioning Equipment
Provide decommissioning equipment required to clean and
mothball the plant.

4. Clean And Mothball Plant


Clean the plant and establishing any maintenance conditions
such that the plant could be returned to operation.
4.1 Clean Plant
Clean the plant internally and externally prior to mothballing.
4.2 Mothball plant
Put the plant in a state such that its condition is preserve so
that the plant could be returned to operation or demolished.
4.3 Archive Records
The archiving of all records associated with the plant to meet
regulatory requirements or recommissioning requirements.
4.4 Determine Inspection Requirements
Determine any inspection requirements from regulatory
bodies.
4.5 Finalise Regulatory Approvals
Finalise any agreements with regulatory bodies that the plant
site has met all requirements.

DECOMMISSION PLANT

DEMOLISH PLANT AND RESTORE SITE


MAINTAIN
EQUIPMENT

Define
Demolition &
Restoration
Requirement

Define
Demolition
Requirements

Plan
Demolition
& Restoration

Produce
Demolition
Procedures

Define
Restoration
Requirements

Produce Resource
Estimates

Perform Safety &


Environment Study

Produce
Demolition &
Restoration
Plan

Prepare
for Plant
Demolition

Obtain Equipment
Records
Obtain Plant &
Equipment Drawings
Obtain Maintenance
Procedures
Obtain Resources

Demolish &
Secure Plant

Prepare Site
Remove
Plant
Dispose of
Plant
Box up &
Secure Plant
To Remain

Obtain Work Permits

Restore
Site

Dispose of
Site

Survey Site
Contamination
Remove / Treat
Contaminated
Material

Archive Records
Finalize
Regulatory
Approval

Dispose of
Contaminated
Material
Restore
Environment

Obtain Inspection
Reports

Disposal Records
Restoration Records
Handover Records
Final Regulatory Approvals

P Harrow colact1 PISTEP 26/04/94

DEMOLISH PLANT AND RESTORE SITE


The activity of taking a plant out of operating service, isolating all feedstock and services, removing all process materials from the plant,
and establishing maintenance conditions such that the plant could be returned to operating service.
1. Define Demolition & Restoration Requirement
Identify the current plant and equipment status, the demolition
and restoration requirements and any hazards involved in
implementing demolition.
1.1 Define Demolition Requirements
Identify demolition requirement for the plant.
1.2 Define Restoration Requirements
Identify the restoration requirement for the plant.
1.3 Perform Safety & Environment Study
Perform a safety and environment study to ensure that the
plant may be demolished in a safe manner without hazard to
personnel or the environment.
2. Plan Demolition And Restoration
Identify the current plant status and produce the demolition and
restoration plans.
2.1 Produce Demolition Procedures
Identify any hazards involved with the demolition and
restoration activities and define procedures to manage them
in a safe manner.
2.2 Produce Resource Estimates
Produce estimates for the resources required for the
demolition or restoration of the plant.

2.3 Produce Demolition And Restoration Plan


Produce a demolition and restoration plan which identifies all
demolition and restoration activities, their time and resource
requirements and dependencies.
3. Prepare Plant For Demolition
Prepare the plant for demolition.
3.1 Obtain Equipment Records
Obtain the records for each item of equipment to be
demolished.
3.2 Obtain Plant and Equipment Drawings
Obtain the drawings for the plant and each item of equipment
to be demolished.
3.3 Obtain Maintenance Procedures
Obtained the procedures which provided information for
performing the maintenance or inspection of the equipment
to be demolished.
3.4 Obtain Resources
Obtain the resources in personnel, spares and special tools
required to perform the demolishment of the equipment.
3.5 Obtain Work Permit
Obtain an authorisation for work and the conditions
necessary for it to be carried out safely.

3.6 Obtain Inspection Reports


Obtain the inspection report that gives the state of equipment
items with details of conditions inspected e.g. Test Pressure.
4. Demolish And Secure Plant
Demolish, remove and dispose of plant. Secure plant to remain.
4.1 Prepare Site
Prepare the site for demolition of the plant.
4.2 Remove Plant
Remove from site the demolished plant.
4.3 Dispose of Plant
Dispose of plant items and materials.
4.4 Box-Up And Secure Plant To Remain
Establish any maintenance conditions for plant to remain on
site.
5. Restore Site
Restore the site to meet environmental requirements or prepare
the site for new plant.
5.1 Survey Site Contamination
Perform a survey of site contamination.
5.2 Remove / Treat Contaminated Material
Remove or treat material from the site which may prove a
hazard subsequent to the restoration of the site.
5.3 Dispose of Contaminated Material
Dispose of any contaminated material in a safe and approved
manner.
5.4 Restore Environment
Restore the site to a condition approved by regulatory bodies.
Typical activities here would be reset drains, landscaping etc.
6. Dispose of Site

Transfer responsibility for the plant from the demolition team to


the site owner, documented by a handover certificate.
6.1 Archive records
Archive all records associated with the demolition and
restoration of the site.
6.2 Finalise Regulatory Approval
Obtain regulatory body approval that the site has been
correctly restored and is fit for disposal.