Detailed Engineering Design Phase

Engineering Design Integrity Workow

Introduction
Detailed Design Engineering Design Integrity Workow (EDIW)
EDIW is AMECs best practice guidance to Engineering Managers and supporting personnel for the delivery of technical integrity. It is an aide-memoir that highlights the key deliverables and activities throughout the lifecycle of a typical Detailed Design project.
Detailed Design is broken into seven phases: 1 Scope Denition and Engineering Execution Strategy 2 Commencement of Detailed Design 3 Initial Design Development and Hazard Identication 4 Initial Design Review & Audit 5 Approval for Design (AFD) 6 Approval for Construction (AFC) 7 Design Close-Out The workow shown in the EDIW Road Map illustrates the execution sequence on a generic Detail Design Project. The vertical columns show activities that can be undertaken concurrently whilst the sequential ow of work is across the Road Map. As the deliverables and activities in each phase are completed, work can transition into the next phase. Situations will arise when work will need to be be done out of sequence, typically to meet a demanding project schedule. Use of the EDIW allows the risks of out-of-sequence working to be identied and the necessary mitigation strategies to be put in place. AMECs corporate governance and assurance of Engineering will measure compliance with the EDIW workow and ensure out-of-phase working is being identied and managed. This document contains a copy of the Detail Design EDIW Workow Road Map and includes detailed descriptions of the activities, the key engineering disciplines and supporting documentation.

Phase 1

Scope Denition and Engineering Execution Strategy

Preparation for commencement of detail design. To evaluate FEED deliverables to ensure engineering is sufciently mature for detail design to progress in a controlled and minimal change environment. To conrm Engineering Execution Plan.
Activities / Deliverables Description
Review / conrm Engineering Execution Strategy, e.g. execution locations, workshare, disciplines required, specialist support, etc. Conrm maturity of Front End Engineering Design. Identify any areas of concern and ensure these are captured on the Technical Risk Register. Establish which codes, standards and specications are to be utilised, eg. Corporate, project, client, and conrm procedure. Include in Engineering Execution Plan and / or Discipline Job Design Specications. Create formal schedule to identify when technical integrity audits, design reviews, HAZIDS, HAZOPS, etc are to be carried out. Align to Level 3 Engineering Plan and include in Engineering Execution Plan. Create Engineering Execution Plan complete with key supporting documents / information. Agree engineering design tools to be used and conrm that system hardware, software and support is available. Include issues such as PDMS or PDS, Cats and Specs, survey methods, dimensional control techniques, etc. Document and record in the Engineering Execution Plan and discipline job design specications. Establish status of project Quantitative Risk Assessment (QRA), Fire Risk Assessment (FRA) and Emergency Escape & Rescue Assessment (EERA) information and conrm methadology for timely delivery into engineering design process. Agree accountability for delivery, eg. Client, 3rd party, AMEC, and record in Engineering Execution Plan. Dene the key project specic design parameters and operational constraints that are applicable to the appropriate discipline for the detailed design of the project. To identify key individuals, roles and responsibilities, design tools, key codes and standards, etc. Agree work breakdown structure, develop CTRs and create level 3 integrated engineering plan covering all disciplines. To be included in Engineering Execution Plan.

Key Discipline
Project Manager and Project Engineering Manager Project Engineering Manager Project Engineering Manager Project Engineering Manager Project Engineering Manager

Supporting Documentation

Engineering Execution Strategy

Tender documentation, Project Execution Plan (PEP)

Feed / BoD Validation

Project Baseline Standards

Engineering Baseline Standards, Document No. OAG-X160-190-GDL-012 (previously AOD-92-043 )

Engineering Audit Schedule Engineering Execution Plan & Engineering Organisation Chart

Technical Safety Events Schedule (Lead Technical Safety Engineer)

Integrated Engineering Systems

Engineering Systems and All Disciplines

Engineering Systems Project Start-up Manual, Document No. OAGX160-170-MAN-002

QRA & FRA Strategy

Technical Safety

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

Discipline Job Design Specication

All Disciplines

Level 3 Engineering Plan

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

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Conrm CE Compliance Strategy

Review and conrm strategy for CE Compliance . Ensure discipline Lead Engineers are aware of their responsibilities and appropriate resources / measures are in place.

Project Engineering Manager

11

Technical Risk Register

Create formal Technical Risk Register identifying all possible risks asscociated with the engineering design.

Techncal Safety

Phase 2

Commencement of Detail Design

To formally kick off the Engineering Design Process in accordance with the project execution plan and to ensure that key engineering strategies / philosophies are in place.
Activities / Deliverables
Performance Standards & Verication Scheme

Description
Conrm safety critical systems / elements and set appropriate performance standards. i.e. functionality, reliability and survivability. Develop scheme to allow the independent competent body (ICB) to verify the design against the performance standards. Create formal document distribution matrix to ensure all disciplines & departments receive all necessary design information in a timely manner. Ensure structural integrity interfaces are identied & visible to Project, e.g. AMEC / Client focal points, Technical Authorities, Independent Verication Bodies, etc. Report dening the requirements and specications of necessary material. Create Hazard Management Plan identifying all key hazards, technical safety activities and the approach to managing Major Accident Hazards (MAH) in the design. Develop / conrm baseline piping specications, utilising AMEC Corporate specications where possible.

Key Discipline
Technical Safety

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

Document Distribution Matrix Structural Integrity Interface Material Selection Report Hazard Management Plan Piping Specications

Project Engineering Manager Structural AMEC Corporate Material Engineering Specications. Hazard & Risk Management, OAG-X160-190PRO-024; Management of Functional Safety Guideline OAG-X160-190-GDL-004 AMEC Corporate Piping Specications.

3 4 5 6

Metallurgy Technical Safety Piping Engineering Systems, supported by Piping, Electrical, Instruments, Structural & HVAC

PDMS Calalogues

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

CMSS Philosophy

Develop Control Monitoring and Safety Systems (CMSS) Philosophy covering key instrumentation and control systems e.g. Process Control System (PCS), Emergency Shutdown System (ESD) and Fire and Gas (F&G).

Instruments

Phase 3

Initial Design Development and Hazard Identication

To develop initial design deliverables to Inter Discipline Review (IDC) stage and identify key hazards.
Key Discipline
Technical Safety Technical Safety Process Process Process Process and Instruments Piping and Layouts Technical Safety

Activities / Deliverables 1
HAZID

Description
Perform hazard identication studies, as identied on Engineering Audit Schedule / Technical Safety Events Schedule. Formal assessment of environmental aspects associated with a modication or a change, and to propose prevention or mitigating measures. Issue Process Flow Diagrams (PFDs) on formal Inter-Discipline Review (IDC). Explain the measures to prevent and control blowdown and how this will be achieved. Issue Piping & Instrumentation Diagrams (P&IDs) on formal Inter-Discipline Review (IDC). Issue Cause & Effects for formal Inter-Discipline Review (IDC). Issue equipment Plot Plans / Layouts on formal inter-Discipline Review (IDC). Issue Hazardous Area Layouts for formal Inter-Discipline Review (IDC). Create master project equipment list identifying all major items of tagged equipment, e.g. vessels, pumps, motors, generators, hydrocycolnes, chemical injection packages, electrical switchgear, control panels, etc. Develop Mechanical Handling Strategy including general approach / constraints, platform crane limits, installation philosophy, operation and maintenance, etc. Where required, i.e. where Corporate PMAs or EAMs are not suitable, develop new PMAs and obtain approval from Notied Bodies (NoBos). Determine Fire & Explosion scenarios and identies requirements for prevention, control and mitigation measures. Identify requirements for emergency escape & rescue, e.g. lifeboats, escape routes, plant layout, etc Identify and assess the potential risks to drilling, production, process equipment, and manned areas from dropped or swinging objects. Where the consequence of a dropped object is considered signicant, to propose prevention or mitigating measures. Develop philosophy that assesses potential explosion hazards and identies appropriate blast loadings to be applied to the engineering design process, eg. Vessels, pipe supports, structural steel, etc. Develop philosophy that identies requirements for Passive Fire Protection (PFP) and/or Active Fire Protection (AFP). Initial review to establish requirements for a High Integrity Pressure Protection System.

Supporting Documentation
Project Hazard Identication (HAZID) AOD-92018; Engineering & Design Reviews, OAG-X160190-PRO-013. Environmental Impact Identication (ENVID) OAG-X160-190-PRO-121; Engineering & Design Reviews, OAG-X160-190-PRO-013.

2 3 4 5 6 7 8

ENVID

PFD IDC Shutdown & Blowdown Philosophy P&IDs IDC C&E IDC Plot Plans / Layouts IDC Hazardous Area Layouts IDC

Equipment List

Mechanical

10

Mechanical Handling Strategy Particular Material Appraisals (PMA) Fire Risk Assessment (FRA) Emergency Escape & Resecue Assesment (EERA)

Mechanical and Structural PED Focal Point Technical Safety Technical Safety

11

12

13

14

Dropped Object Study

Technical Safety

15

Blast Design Philosophy

Technical Safety

16 17

PFP / AFP Philosophy

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

HIPPS Review

Phase 4

Initial Design Review and Audit

To conrm that the initial design development is robust.
Activities / Deliverables 1
Hazardous Area Review

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

Key Discipline
Technical Safety Process, Piping, Technical Safety, Instruments Piping and Layouts, Structural, Mechanical, Electrical, Technical Safety, Process Instruments, Process, Technical Safety Independent (Corporate Engineering)

Supporting Documentation
Hazard and Risk Management Procedure OAG-X160-190-PRO-024; Engineering & Design reviews, OAG-X160-190-PRO-013 Formal Hazop, OAG-X160-190-PRO-017; Engineering & Design Reviews, OAG-X160-190PRO-013

P&ID Review and / or Initial Hazop

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

Plot Plans / Layout / 3-D Model Review

Formal Engineering review of Plot Plans / Layouts. The review shall ensure that the layout design complies with the required technical, safety, operability and maintainability standards. Makes sure the layout is cost effective, ensures the constructability of the work and agrees the layout basis on which the detailed design can proceed. Formal review of Cause & Effects diagrams to conrm design basis and alignment with Hazard Management Plan. Obtain conrmation, by sampling of project documentation, that the engineering of the project is to the required standard and free from errors.

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

C&E Review

Hazard and Risk Management Procedure OAG-X160-190-PRO-024; Engineering & Design reviews, OAG-X160-190-PRO-013; Management of Functional Safety Guideline OAG-X160-190-GDL-004 Technical Audit Procedure OAG-X160-190-PRO-022

Technical Audit

Phase 5

Design Approval
To Freeze the Process design, and develop dependent design & procurement activities.
Activities / Deliverables 1
PUWER Assessments

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

Key Discipline
Technical Safety, Mechanical

Supporting Documentation
Engineering & Design Reviews, OAG-X160-190-PRO-013 Dependent on Project updated P&IDs and C&Es may be prepared from commented IDCs from Phase 3 Formal HAZOP, OAG-X160-190PRO-017 (previously AOD-92-022); Engineering & Design Reviews, OAG-X160-190-PRO-013 - Note: additional HAZOPs may be required, i.e. earlier or later in the project. PEM to consult with Process & Technical Safety Lead Engineers. SHE Audit Procedure OAG-X160-190-PRO-023; Engineering & Design Reviews, OAG-X160-190PRO-013

HAZOP

Hazard and Operability Studies, a systematic multi-discipline study based on the applications of guidewords to identify causes of potential hazards and operability constraints in a facility.

Process, Technical Safety

SHE Audit (AFD)

SHE Audit ensures that the design obligations under The Health and Safety At Work Act 1974 and project health, safety and environmental performance standards are being or have been met during the engineering and design processes. Issue nal report to document & conrm that the design has considered all applicable environmental aspects & demonstrates that design controls have been included to minimise / control the environmental impact.

Technical Safety

Environmental Report

Technical Safety Affected disciplines + Construction / Implementation Group Process Instruments Process

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

Constructability Review

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

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

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P&ID AFD C&E AFD Process Data Sheets AFD HP / LP Interface Listing Holds Register

Issue Approved For Design (AFD) Process and Instrumentation Diagrams. Issue Approved For Design (AFD) Cause & Effects. Issue Approved For Design (AFD) Process Data Sheets. Identify all HP / LP interfaces on formal register and ensure that all have been addressed satisfactorily via HAZOPs and / or individual reviews. Develop register to record & manage post AFD design holds. Conduct assessment to determine target Safety Integrity Level (SIL). Note: Where the target SIL is 3, then it is likely that a High Integrity Pressure Protection System (HIPPS) will be required. If the value is found to be 1 or 2, then a HIPPS will not be required. Conduct study to formally identify the performance requirements of the High Integrity Pressure Protection System (HIPPS) and demonstrate that it is robust. Should include dynamic study for a range of transient conditions. Conduct study to formally demonstrate that the High Integrity Pressure Protection System (HIPPS) complies with the reliability & availability criteria for the Project, e.g. as stipulated in the performance standards. Conduct independent assessment to formally record that the target Safety Integrity Levels (SILs have been achieved) Must be completed prior to introduction of Hydrocarbons. Conduct ow assurance studies to demonstrate the process design under a range of ow conditions, i.e. start-up to 100%. Verify, primarily through review of vendor documentation, that their design & manufacture of fabricated packages, etc is robust and contains sufcient information to facilitate completion of affected AMEC discipline design. Issue nal report as documented conrmation that the design meets the requirements of the Prevention of Fire and Explosion, and Emergency Response (PFEER) Regulations

Process Engineering Manager

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SIL Assessments

Instruments

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

12

HIPPS Study

Process

Management of Functional Safety, OAG-X160-190-GDL-005

13

HIPPS Reliability Study

Instruments

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

14 15

SIL Achievement Report Flow Assurance Verication of Vendor Information & Certication Design Completion PFEER Compliance Report

Independent Competent Person (ICP) Process

Management of Functional Safety, OAG-X160190-GDL-004

16

Affected disciplines

17

Technical Safety

Phase 6

Approval for Construction (AFC)

To ensure that sufcient design information & certication is available to facilitate safe installation, operation & maintenance.
Activities / Deliverables 1 2 3 4 5 6 7 8 9
SHE Audit AFC IEC 61511 Compliance Report PFDs AFC Operational Safety Case Development P&IDs AFC Quantative Risk Assessment (QRA) C&E AFC Operating Procedures Review / Operational HAZOP Fabrication Drawings AFC Verication of Vendor Information & Certication Installation, Operation & Maintenance EC Design Examination Certicates Declaration of Conformity

Description
Conduct SHE Audit at AFC stage in accordance with Harmonised Procedure. Final report to formally demostrate that the Safety Instrumented Systems comply with the requirements of IEC 61511. Issue Approved For Construction (AFC) Process Flow Diagrams. Commence operational Safety Case development. Issue Approved For Construction (AFC) Process and Instrumentation Diagrams. Complete QRA activities to conrm that the design is robust and complies with legislative requirements. Issue Approved For Construction (AFC) Cause & Effects. Ensure operating procedures are veried line by line against the facilities provided on the P&IDs. Issue Approved For Construction (AFC) Piping Isometrics, Structural Steelwork drgs, etc. Verify, primarily through review of vendor documentation, that their design & manufacture of fabricated packages, etc is robust and contains sufcient information to facilitate safe installation, operation & maintenance. Where AMEC are deemed to be the manufacturer of the piping systems, then under the PED/PER, AMEC have to apply to the Notied Body (NoBo) for an EC Design Examination Certicate (Cat IV assemblies only). Where AMEC are deemed to be the manufacturer of the piping systems, then under the PED/PER, AMEC have to create a Declaration of Conformity, signed by the Project Manager.

Key Discipline
Technical Safety Instruments

Supporting Documentation
SHE Audit Procedure OAG-X160-190-PRO-023 Management of Functional Safety, OAG-X160190-GDL-004

Process Technical Safety Process Technical Safety Instruments Process, Technical Safety Affected Disciplines Formal HAZOP, OAG-X160-190-PRO-017 (previously AOD-92-022); Engineering & Design Reviews, OAG-X160-190-PRO-013

10

Affected Disciplines

11

PER Focal point

Project Compliance with the Pressure Equipment Directive, Document No. OAG-X160-190-GDL-007. Project Compliance with the Pressure Equipment Directive, Document No. OAG-X160-190-GDL-007.

12

Project Manager

Phase 7

Design Close-Out
To ensure all nal design deliverables are completed and that client and statutory obligations are satisfactorily resolved.
Activities / Deliverables 1
Safety Case Acceptance (HSE) Certifying Authority (CA) / Independent Verication Bodies (IVB) Acceptance Complete Project As-Built Documentation

Description
Submit Safety Case to HSE & close out all queries / correspondance prior to next stage of operations. Close out all outstanding technical queries and obtain nal Letter of Acceptance.

Key Discipline
Technical Safety Technical Safety

Supporting Documentation

Complete as-builts of design drawings and deliverables in accordance with Project / Client requirements.

Affected Disciplines

As Built Drawings and Documentation, AOD-92-021

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