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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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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
MANAGEMENT ACTIVITIES
SET ENGINEERING
POLICY &
STANDARDS
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
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
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
DECOMMISSION
PLANT
Plant Status
Plant Records
Inspection Requirements
Regulatory Approvals
CONSTRUCT &
PRE-COMMISSION
PLANT
PRODUCE DETAILED
ENGINEERING
DESIGN
Materials & Equipment
Requirements & Specifications
Required on Site Dates
As Built Drawings
Operating Procedures
Acceptance Test results
Handover Certificate
State of Equipment
Value of Equipment
Equipment Records
MAINTAIN
EQUIPMENT
Disposal Records
Restoration Records
Handover Records
Final Regulatory Approvals
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.
Identify
Candidate
Processes
Define End
Requirements
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
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
Identify all features of the process and plant which are subject to
regulatory requirements and produce design philosophies to
meet those requirements.
PRODUCE
DETAILED
ENGINEERING
DESIGN
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 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.
PRODUCE CONCEPTUAL
PROCESS DESIGN
COMMISSION
PROCESS &
COMMISSION
PLANT
Produce
Functional
Specification
for Equipment
Produce
Control
Requirements
Specification
Identify
Control
Requirements
Identify Trip
Requirements
Define Protective
System (Including Fire)
Philosophy
Produce
Control
Requirements
Specification
PRODUCE
DETAILED
ENGINEERING
DESIGN
Satisfy Safety
Requirements
Produce
Plant
Operating
Procedures
Performance Requirements
Operating Procedures
Operating Conditions
Alarm / Trip Settings
Safety and Environment
Case
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
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
CONSTRUCT &
PRE-COMMISSION
PLANT
SUPPLIERS &
FABRICATORS
PRODUCE
DETAILED
ENGINEERING
DESIGN
CONSTRUCT &
PRE-COMMISSION
PLANT
MAINTAIN
EQUIPMENT
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
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
COMMISSION PROCESS
& HANDOVER PLANT
As Built Drawings
Equipment Commissioning Procedures
Equipment Operating Procedures
Inspection & Testing Records
Handover Certification
P
MAINTAIN
EQUIPMENT
ENGINEERING
DESIGN
Produce
Contract
Plan
Produce
Construction
Plan
Establish
Construction
Services
Erect
Plant
Produce
As-Built
Surveys
Pre-Commission
Perform
Civil /
Structural
Construction
Perform
Conformance
Checks
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
PRODUCE
DETAILED
PROCESS
DESIGN
OPERATE
PLANT
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
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
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
MAINTAIN
EQUIPMENT
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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.
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OPERATE
PLANT
Inspection Requirements Work
Permit Requests Notification of
Work Completion
MAINTAIN EQUIPMENT
CONSTRUCT &
PRE-COMMISSION
PLANT
Define
Maintenance
Approach
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
Perform
Maintenance
or Inspection
Identify Inspection
Requirements
Obtain Maintenance
Procedures
Obtain Resources
Obtain Maintenance
Procedures
DEMOLISH PLANT
& RESTORE SITE
State of Equipment
Value of Equipment
Equipment Records
Record
Resources
Consumed
Update
Equipment
Records
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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.
37
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
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.
DECOMMISSION PLANT
Define
Demolition &
Restoration
Requirement
Define
Demolition
Requirements
Plan
Demolition
& Restoration
Produce
Demolition
Procedures
Define
Restoration
Requirements
Produce Resource
Estimates
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
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