Feed Phase Engineering Design Integrity

FEED Phase

1

Introduction

FEED Engineering Design Integrity Workfl ow (EDIW)

EDIW is AMEC’s best practice guidance to Engineering Managers and supporting

personnel for the delivery of technical integrity. It is an ‘aide-memoir’ that highlights

the key deliverables and activities throughout the lifecycle of a typical FEED project.

FEED is broken into six phases:

1

Scope

Defi nition and Engineering Execution Strategy

2

Commencement of FEED Design

3

Initial FEED Development and Hazard Identifi cation

4

Initial Design Review & Audit

5

FEED Design Approval (AFD)

6

Final Reviews and Feed Report Compilation

The workfl ow shown in the EDIW Road Map illustrates the execution sequence on a generic

FEED Project. The vertical columns show activities that can be undertaken concurrently whilst the

sequential fl 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

identifi ed and the necessary mitigation strategies to be put in place.

AMEC’s corporate governance and assurance of Engineering will measure compliance with the

EDIW workfl ow and ensure out-of-phase working is being identifi ed and managed. This document

contains a copy of the FEED EDIW Road Map and includes detailed descriptions of the

2

Phase 1

Scope Defi nition and Engineering Execution Strategy

Preparation for commencement of detail design. To evaluate FEED deliverables to ensure

engineering is suffi ciently mature for detail design to progress in a controlled and minimal

change environment. To confi rm Engineering Execution Plan.

Activities / Deliverables

Description

Supporting Documentation

1

Engineering Execution Plan & Engineering Organisation Chart

Create Engineering Execution Plan complete with key supporting documents / information.

2

Preparation/Validation of Conceptual Study Report/ BoD

Confi rm maturity of Conceptual Design report. Identify any areas of concern and ensure these are captured on the Technical Risk Register.

3

Project Baseline Standards

Establish which codes, standards and specifi cations are to be utilised, e.g.. Corporate, project, client, and confi rm procedure. Include in Engineering Execution Plan and/or Discipline Job Design Specifi cations.

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

4

Engineering Audit Schedule

Create formal schedule to identify when technical integrity audits, design reviews, HAZIDS, HAZOPS, etc are to be carried out. Align to Level 3 Engineering Plan and include in Engineering Execution Plan.

Technical Safety Events Schedule (Lead Technical Safety Engineer)

5

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

6

Integrated Engineering

Systems

Agree engineering design tools to be used and confi rm 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 specifi cations.

Engineering Systems Project Start-up Manual, Document No. OAG-X160-170-MAN-003

7

QRA & FRA Strategy

Establish status of project Quantitative Risk Assessment (QRA), Fire Risk Assessment (FRA) and Emergency Escape & Rescue Assessment (EERA) information and confi rm methodology for timely delivery into engineering design process. Agree accountability for delivery, e.g.. Client, 3rd party, AMEC, and record in Engineering Execution Plan.

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

8

Discipline Job Design

Specifi cation

Defi ne the key project specifi c design parameters and operational constraints that are applicable to the appropriate discipline for the detailed design of the project. To identify key individuals , roles and responsibilities, design tools, key codes and standards, etc.

9

Level 3 Engineering Plan

Agree work breakdown structure, develop CTRs and create level 3 integrated engineering plan covering all disciplines. To be included in Engineering Execution Plan.

10

Confi rm CE Compliance

Strategy

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

Corporate CE Compliance Strategy OAG-X160-190-MAN-001; Project Compliance with Pressure Equipment Regulations OAG-X160-050-PRO-001; Pressure Equipment Regulations Guidelines AOD-97-047; ATEX Guidelines, OAG-X160-190-GDL-003; Machinery Directive Guidelines, O&G-ENG-REP-29-001; Electromatic Compatibility Regulations Guidelines, OAG-X160-190-GDL-003; MC, The Electrical Equipment (Safety) Regulations Guidelines, OAG-X160-190-GDL-003.

11

Prepare Interface Register Develop interface register to ensure all interfaces are identifi ed and managed.

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

3

Phase 2

Commencement of FEED Design

To formally kick off the Engineering Design Process in accordance with the project execution plan

and to ensure that key engineering strategies / philosophies are in place.

Activities / Deliverables

Description

Supporting Documentation

1

Safety Critical Systems/ Elements and Performance Standards

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

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

2

Document Distribution

Matrix

Create formal document distribution matrix to ensure all disciplines & departments receive all necessary design information in a timely manner.

3

Structural Integrity

Interface

Ensure structural integrity interfaces are identifi ed & visible to Project, e.g. AMEC / Client focal points, Technical Authorities, Independent Verifi cation Bodies, etc.

4

Material Selection Report Report defi ning the requirements and specifi cations of necessary material.

AMEC Corporate Material Engineering Specifi cations.

5

Hazard Management Plan

Create Hazard Management Plan identifying all key hazards, technical safety activities and the approach to managing Major Accident Hazards (MAH) in the design.

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

6

Piping Specifi cations Develop / confi rm baseline piping specifi cations, utilising AMEC

Corporate specifi cations where possible. AMEC Corporate Piping Specifi cations.

7

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

8

CMSS Philosophy The purpose of this task is to defi ne and prepare the assurance activities to be undertaken aligned with the project categorisation.

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

Phase 3

Initial Design Development and Hazard Identifi cation

To develop initial design deliverables to Inter Discipline Review (IDC) stage and identify

key hazards.

Activities / Deliverables

Description

Key

Discipline

Supporting Documentation

1

HAZID

Perform hazard identifi cation studies, as identifi ed on Engineering Audit Schedule / Technical Safety Events Schedule.

Technical Safety

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

2

ENVID

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

Technical Safety

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

3

PFD IDC Issue Process Flow Diagrams (PFD’s) on formal

Inter-Discipline Review (IDC). Process

4

Shutdown & Blowdown _Philosophy Explains the measures to shutdown safely and control _{blowdown and how this will be achieved.} Process

5

P&ID’s IDC Issue Piping & Instrumentation Diagrams (P&ID’s) on

formal Inter-Discipline Review (IDC). Process

6

Plot Plans / Layouts IDC Issue equipment Plot Plans / Layouts on formal inter-Discipline Review (IDC).

Piping and Layouts

7

HIPPS Review Initial review to establish requirements for a High

Integrity Pressure Protection System. Instruments

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

8

Dropped Object Study

Identify and assess the potential risks to drilling, production, process equipment, and manned areas from dropped or swinging objects. Where the consequence of a dropped object is considered signifi cant, to propose prevention or mitigating measures.

Technical Safety

9

Mechanical Handling

Strategy

Develop Mechanical Handling Strategy including general approach / constraints, platform crane limits, installation philosophy, operation and maintenance, etc.

Mechanical and Structural

10

Particular Materia_{Appraisals (PMA)}

Where required, i.e. where Corporate PMA’s or EAM’s are not suitable, develop new PMA’s and obtain approval from Notifi ed Bodies (NoBo’s.

PED Focal Point

11

C&E IDC Issue Cause & Effects for formal Inter-Discipline Review (IDC).

Process and Instruments

12

Hazardous Area Layouts

IDC

Issue Hazardous Area Layouts for formal Inter-Discipline Review (IDC).

Technical Safety

13

Fire Risk Assessment

(FRA)

Determines Fire & Explosion scenarios and identifi es requirements for prevention, control and mitigation measures.

Technical Safety

14

Blast Design Philosophy

Develop philosophy that assesses potential explosion hazards and identifi es appropriate blast loadings to be applied to the engineering design process, e.g.. Vessels, pipe supports, structural steel, etc.

Technical Safety

15

TR Impairment Study

Assessment of the vulnerability of a Temporary Refuge and demonstration of its capability to sustain life for a specifi ed duration when under attack by fi re, explosion and toxic gases.

Technical Safety

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

16

Equipment List & Data _Sheets

Create master project equipment list identifying all major items of tagged equipment, e.g. vessels, pumps, motors, generators, hydrocycolnes, chemical injection packages, electrical switchgear, control panels, etc.

Mechanical

17

Emergency Escape & Rescue Assessment (EERA)

To identify requirements for emergency escape & rescue, e.g. lifeboats, escape routes, plant layout, etc.

Technical Safety

18

PFP / AFP Philosophy

Develop philosophy that identifi es requirements for Passive Fire Protection (PFP) and/or Active Fire Protection (AFP).

Technical Safety

19

Power System Analysis Check power system capacities for increase power

requirements for new equipment (Brownfi eld). Electrical

20

Preliminary Weight _Report Prepare preliminary Weight report. Structural

5

Phase 4

Initial Design Review and Audit

To confi rm that the initial design development is robust.

Activities / Deliverables

Description

Key

Discipline

Supporting Documentation

1

Hazardous Area Review

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

Technical Safety

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

2

P&ID Review Formal Engineering discipline review of P&ID's to confi rm design basis.

Process, Piping, Technical

Safety, Instruments

3

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

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

4

C&E Review

Formal review of Cause & Effects diagrams to confi rm design basis and alignment with Hazard Management Plan.

Instruments, Process, Technical

Safety

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

5

Technical Audit

Obtain confi rmation, by sampling of project

documentation, that the engineering of the project is to the required standard and free from errors.

Independent (Corporate Engineering)

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

6

Phase 5

FEED Design Approval (AFD)

To ‘Freeze’ the Process design, and develop dependent design & procurement activities.

Activities / Deliverables

Description

Key

Discipline

Supporting Documentation

1

Final Design review Demonstartion that all of the design and review activities

relevant to achieving design integrity have been performed.

Technical

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

2

PUWER

Assessments

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

Technical Safety, Mechanical

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

3

HAZOP

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

Process, Technical

Safety

Dependent on Project updated P&ID’s and C&E’s may be prepared from commented IDC’s from Phase 3 Formal HAZOP, OAG-X160-190-PRO-017 (previously AOD-92-022); Engineering & Design Reviews, OAG-X160-190-PRO-013 - Note: additional HAZOP’s may be required, i.e. earlier or later in the project. PEM to consult with Process & Technical Safety Lead Engineers.

4

BAT Report

The Final report which analyses the major environmental issues that have been considered as part of the process to select the fi nal option from the various alternatives considered. Thus preventing, or eliminating, or where the alternatives are not practicable, to then limit or reduce environmental impacts associated with the selected option.

Technical Safety

Procedure for Selection of Best Available Techniques (BAT) Procedure No: OAG-X160-190-PRO-030

5

Constructability

Review

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

Affected disciplines + Construction /

Implementa-tion Group

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

6

P&ID AFD Issue Approved For Design (AFD) Process and

Instrumentation Diagrams. Process

7

C&E AFD Issue Approved For Design (AFD) Cause & Effects. Instruments

8

Process Data Sheets

AFD Issue Approved For Design (AFD) Process Data Sheets. Process

9

HP / LP Interface

Listing

Identify all HP / LP interfaces on formal register and ensure that all have been addressed satisfactorily via HAZOP’s and / or individual reviews.

Process

10

Holds Register Develop register to record & manage post AFD design holds. Engineering Manager

11

SIL Assessments

Conduct assessment to determine target Safety Integrity Level (SIL). Note: Where the target SIL is 3, then it is likely that a High Integrity Pressure Protection System (HIPPS) will be required. If the value is found to be 1 or 2, then a HIPPS will not be required.

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

12

HIPPS Study

Conduct study to formally identify the performance requirements of the High Integrity Pressure Protection System (HIPPS) and demonstrate that it is robust. Should include dynamic study for a range of transient conditions.

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

13

Qualitative Risk

Assessment (QRA)

Multi-disciplinary study of hazards, the likeihood of their occurrence and potential consequences in terms of harm to people and the environment.

Technical Safety

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

14

HIPPS Reliability

Study

Conduct study to formally demonstrate that the High Integrity Pressure Protection System (HIPPS) complies with the reliability & availability criteria for the Project, e.g. as stipulated in the performance standards.

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

15

Flow Assurance Conduct fl ow assurance studies to demonstrate the process

design under a range of fl ow conditions, i.e. start-up to 100%. Process

16

EDAS Stage Gate

Reviews

Demonstrate adherence to the EDAS Task Performance Crite-ria appropCrite-riate for Project Category.

Engineering Management

17

Technical Peer

Review

Demonstrate adherence to the EDAS Task Performance Criteria appropriate for the Project Category and to ensure that engineering personnel are aware of EDASrequirements and adequately explain how those requirements are being fulfi lled.

Engineering Management

Phase 6

Final Reviews and FEED Report Compilation

To ensure all fi nal design deliverables are completed and that client and statutory obligations are

satisfactorily resolved.

Activities / Deliverables

Description

Key

Discipline

Supporting Documentation

1

FEED Report Collate all discipline inputs and fi nalise study report. Project

Management

All Discipline Reports and discipline drawings etc.

AMEC (LSE: AMEC) is a focused supplier of high-value consultancy, engineering and project management services to the world’s natural resources, nuclear, clean energy, water and environmen-tal sectors. With annual revenues of over £2.5 billion, AMEC designs, delivers and maintains strategic and complex assets for its customers. The company employs some 22,000 people in around 40 countries worldwide.