Deliverables list for Projects in the fertilizer industry

Transcription

1 Deliverables list for s in the fertilizer industry Document Development Guidance Department: s / Engineering Revision 1 August 2018 Doc. No: AKH01-GUI-ENG-LST-001

2 Contents 1. Synopsis Why develop specific guidelines and procedures Purpose of this document and Document Phases Deliverables of Identify Phase Deliverables for Select Phase Deliverables for Define Phase Deliverables for Execute Phase Deliverables for Operate Phase Applicability Responsibility Develop your own organization procedures Definitions

3 1. SYNOPSIS AmmoniaKnowHow.com and UreaKnowHow.com support fertilizer manufacturers by providing essential services to the industry, using our syngas technologies and scientific knowledge developed in multiple projects worldwide. Together we initiate a program to enhance the guidelines and procedures for operation, engineering, maintenance and process safety in the fertilizer industry utilizing the best practices and standards available today. Using knowledge gained from our industry, historic risk registers, lessons learned from projects and from FIORDA members we are committed to give proper advice to improve safety, reliability and projects performance of fertilizer plants. 2

4 2. WHY DEVELOP SPECIFIC GUIDELINES AND PROCEDURES Guidelines and Procedures are developed to help staff and management teams run the organization. In the best use situations, procedures play a strategic role in an organization. They are developed in light of the mission and objectives of the company and they become the media by which management s plans, rules, intents, and business and operation processes become documented and communicated to all staff. Carefully drafted and standardized guidelines and procedures save the company countless hours of management time. Guidelines, procedures and employee handbook should be an important part of the operation. They should be the first thing given to a new employee (either in hard copy or an electronic version). They should also be easily accessible in their most up-to-date version. Hence it is extremely important that an organization s procedures are a living document prepared and saved in Microsoft Word and easily exported into portable versions (like PDF) and made available over the company network. 3. PURPOSE OF THIS DOCUMENT Purpose of the Deliverables List for s is to define the basic level of documentation required for each phase of the project and to determine the level of responsibility for each engineering discipline during the review phase of each document. Deliverables List for s document can be used as internal guideline by fertilizer manufactures providing contractors and consultants with clear requirements of deliverables for each project stage. 4. PROJECT AND DOCUMENT PHASES In general, a project is divided in 5 phases: 1. Identify 2. Select 3. Define 4. Execute 5. Operate The number of documents, complexity and level of details increase for each phase while the project progresses. The status of deliverables changes and can be defined as following: Preliminary Updated AFD Work on the deliverable has started; development is typically limited to sketches, rough outlines or similar levels of early completion; A status refers to a level of maturity that is sufficient for a clear definition of the part of the engineering work covered by the document. This also comprises refinement of the Preliminary status as well as cross-functional reviews being conducted. Further Updated is required prior to ization / actual implementation. An Updated status refers to level of maturity, in which the document has been further developed and aligned cross-functionally. stage has not yet been reached. More than one updating cycle may be necessary. "Approved for Design": Engineering work has gone through appropriate steps of review and assurance, enabling the design to be frozen. Commencement of detail-design is the following step. Any significant modification of the document can only be achieved through formal " of Change" process (MoC)." 3

5 A status refers to a level of maturity that is sufficient to proceed with implementation of the engineering work. A deliverable having achieved a status shall not require change in the further course of the implementation. Any significant modification of the document can only be achieved through formal " of Change" process (MoC). Document is issued for the specific project life cycle phase and does not require Update in next phases. 5. DELIVERABLES OF IDENTIFY PHASE During the Identify phase the disciplines involved in the project are in general the, Process and. The status of documentation is Preliminary and and will include process basic functionality of plant, type of plant, basic function, basic interconnection to plant environment (technical, economic, environmental). Examples of deliverables to be developed in the Identify phase are: - Milestone Plan - Risk Plan + Risk Register - Conceptual HAZID study - Time Schedule - Basis of Design - Condition Assessment Studies / Report - Pipeline (ISO-metrics) - general route profile - Block Flow Diagrams - Equipment List - Heat and Material Balances - Process Design Criteria Document - Process Flow Diagrams - Simulation Models, reports and listings - Tie in List - Fluid List - Authority Plan (Permits and Consents Strategy) - Site Identification Report - Stakeholder Register & engagement plan - Etc. 6. DELIVERABLES FOR SELECT PHASE The primary objective of the Selection phase is to demonstrate that the project will provide an acceptable level of risk and financial return as a sound investment for Client. The technical, commercial and financial aspects of the project will be assessed to select the optimal / preferred development and provide a robust case for progressing towards project realisation. In the Select phase more engineering disciplines are getting involved. Civil, Control & Instrumentation,, HSE, Cost Control will have their own deliverables together with, Process and. Document status may vary, depending on discipline for example: Discipline Deliverable Title Document status Civil Geotechnical Report Preliminary 4

6 I/O List Preliminary Instrument Index Preliminary Control System Architecture Diagram Preliminary Equipment List Preliminary Key Single Line Diagram Preliminary Load List Preliminary General Eng. Design Philosophies for all Disciplines Preliminary General Eng. General Arrangement Drawings Preliminary Leak Detection Instrument Index Preliminary Detailed HAZID study Preliminary Coarse HAZOP study Preliminary Hazard and effects register Preliminary Design HSE case concept including ALARP demonstration Preliminary Draft Emergency Response plan Preliminary Calculation Notes for Equipment Preliminary Corrosion and material selection philosophy Preliminary Equipment drawings Preliminary Process Piping & Instrumentation Diagrams Preliminary Process Process Equipment and Systems Datasheets Preliminary Process Process Equipment and Systems Specifications including Utility Preliminary Process Operation and Control Philosophy Preliminary Process Isolation Philosophy Preliminary Process ESD and DCS Philosophy Preliminary Compliance Register and regulatory action plan Preliminary Civil Civil Works Specification(s) Civil Technical Report Civil Geotechnical Data Acquisition Plan General Eng. Basis of Design General Eng. Condition Assessment Studies/ Report 5

7 General Eng. General Plant Layout (Plot Plan) Rotating Equipment Drive Selection Study Report Process Equipment List Process Fluids List Process Heat and Material Balances Process Process Flow Diagrams Process Simulation Models, reports and listings Authority Plan (Permits and Consents Strategy) Risk Plan + Risk Register Process Block Flow Diagrams Updated Process Tie in List Updated Milestone Plan Reports Time Schedule Updated Updated Updated General Eng. Basis of Design (non-process) General Eng. Operation & Maintenance Philosophy General Eng. Spare Parts Strategy Process Process Design Criteria Documents Scope of Work for Services Cost Estimates Risk Register Others 7. DELIVERABLES FOR DEFINE PHASE Define phase means the project work following the select phase and successful FEED Readiness Review and culminating in a FID submission documentation. In this phase, the requirements that are associated with the project result are specified as clearly as possible. This involves identifying the expectations that all the involved parties have with regard to the project result. It is important to identify the requirements as early in the process as possible. Wijnen (2004) distinguishes several categories of project requirements: 6

8 Preconditions Functional requirements Operational requirements Design limitations Discipline Deliverable Title Document status Civil Architectural Drawings for Buildings Civil Civil Works Specification(s) Civil Technical Report Civil Construction Drawings Civil Civil Civil Civil Civil Civil I/O List Instrument Index Control System Architecture Diagram Process Control Narrative Cause & Effect Diagram Control System Specification 7

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10 Equipment List Key Single Line Diagram Load List Cable Routing/overhead line plans Preliminary Preliminary Preliminary Typical installation drawings Preliminary cables List Cathodic Protection System Specification 9

11 (ATEX) Hazardous Areas: Risks assessment of explosions Preliminary (ATEX) (ATEX) Preliminary General Eng. Condition Assessment Studies/ Report Updated General Eng. General Arrangement Drawings General Eng. General Eng. General Eng. General Eng. Basis of Design Identify major risks for C&C (joint SIMOPS and HAZID) Construction readiness review Updated Preliminary Bow-tie analyses Preliminary Design HSE case including ALARP demonstration Updated MAH Report Updated HAZOP study LOPA study Design Safety Review SIMOPS study 10

12 Calculation Notes for Equipment Corrosion and material selection philosophy datasheets (process & utilities equipment, piping, valves) General Arrangement Drawings Specifications (process & utilities equipment, piping, valves) Pressure vessels drawings Preliminary Piping Calculations Piping Classes Specification 11

13 Preliminary Preliminary Preliminary Preliminary Preliminary Process Vessels Sizing Process Draining philosophy Process Equipment List Process Flaring and Blow Down Philosophy Process Fluids List Process Process Process Process Process 12

14 Process Process Process Process Process Process Flow Diagrams Process Draining Philosophy Process Operation and Control Philosophy Process Isolation Philosophy Process ESD and DCS Philosophy Process Commissioning & Start up Philosophy Services Contingency Estimation Services Cost Breakdown Structure Services Cost Estimates Services Services Services Services Services Updated 13

15 Services Services Services Authority Plan (Permits and Consents Strategy) Compliance Register and regulatory action plan Milestone Plan Reports Risk Plan + Risk Register Risk Register Updated Updated Updated Updated 8. DELIVERABLES FOR EXECUTE PHASE In this phase all documents shall be sufficient for the execution phase and checked by an appropriate certified body. Each deliverable shall have a high level of detail and fulfill the purpose for it is produced. Discipline Deliverable Title Document status Civil Architectural Drawings for Buildings Civil Construction Drawings Civil Layouts Civil BoQ's and MTO Civil Calculation Report Civil 14

16 Civil Civil Local Control System Specification Field Instruments Specification Control Room Specification Instrumentation Cables Specification Control Room Layout Drawings Cable Block Diagram 15

17 Logic Diagrams / Hydraulically/ Pneumatic Layouts for Instruments Panel, Cabinet and Desk Layout Drawings Operating philosophy for the power system 16

18 equipment specifications Schedule of protective relaying settings Material take off for all electrical equipment material Cathodic Protection System Specification Calculations (LV) Block Diagrams 17

19 (ATEX) (ATEX) (ATEX) Hazardous Areas Drawing (ATEX) Hazardous Areas: Equipment specifications (ATEX) Hazardous Areas: Materials characteristics, including electrical resistivity (ATEX) Hazardous Areas: Certificate EC (ATEX) Hazardous Areas: Declaration of conformity EC (ATEX) (ATEX) (ATEX) Manufacturer's Declaration for equipment which have not own source of ignition and are considered outside the scope of Directive 94/9/EC Documents for Ex equipment with conditions of use, e.g. for equipment with certificate numbers which have the suffix X (ATEX) (ATEX) (ATEX) (ATEX) (ATEX) (ATEX) 18

20 (ATEX) (ATEX) Hazardous Areas: Report regarding initial inspection (ATEX) Hazardous Areas: Information for Maintenance and repairs (ATEX) Explosion Protection Document (ATEX) General Eng. Condition Assessment Studies / Report General Eng. Operations Readiness Review HAZID and risk assessment (for Construction & Commissioning) - joint SIMOPS and HAZID Construction readiness review Detailed Bow-tie analyses Fire and Explosion Analysis Emergency System Survivability Analysis SIL study/ classification plan (for construction phase) Independent verification of safety critical process control loops 19

21 Leak Detection System Wiring Diagram Calculation Notes for Equipment Corrosion and material selection Philosophy Coating, painting and insulation specifications 20

22 Tie-in details Piping support schedule Piping support details Hydrostatic test diagram 21

23 Pressure vessels internal arrangement drawings Welding specifications and procedures Typical welding detail drawings De-watering and drying specification 22

24 Services Contingency Estimation Services Cost Breakdown Structure Services Cost Estimates Services Progress Measurement System Services Services Services Services Services Services Services Services Work Breakdown Structure Compliance Register and regulatory action plan Reports Risk Plan + Risk Register Risk Register Stakeholder Register & -engagement plan Time Schedule Updated Updated Updated 9. DELIVERABLES FOR OPERATE PHASE Discipline Deliverable Title Document status 23

25 System 10. APPLICABILITY Deliverables List for s is a document owned by the s / Engineering department within the organization. They are responsible to assess the necessity of each deliverable depending on project complexity and scope of work. 11. RESPONSIBILITY A detailed RACI Matrix shall be developed for the following engineering disciplines: - Process Engineering - Engineering - Control & Instrumentation Engineering - Civil Engineering - Static Equipment - Rotating Equipment - Piping, Valves & Pipeline Engineering Services (Cost Estimating & engineering) - Services (Planning & scheduling) Responsibilities can be defined as following: (R) Responsible The accountable person may delegate some of his/her tasks to the responsible person, who then is in charge to achieve this task. The responsible person is the one who delivers the content of a document ("doer"). (A) Accountable The one who is ultimately in charge of completion of the deliverable or task - there is only one accountable person per deliverable / task and this person approves this deliverable. (C) Consulted (I) Informed Sought for their opinion, the consulted person bears expertise to share within the creation process of the deliverable / task. Stakeholders to be directly informed are marked as such to be kept up-to-date upon approval of the deliverable / completion of the task. 12. DEVELOP YOUR OWN ORGANIZATION PROCEDURES Although templates can give you a head start on procedures development, other factors must be considered as you write your own internal documents. One factor is your organization s culture. Organizational attitudes toward procedures determine the spectrum. On one end of the scale are companies that have a procedure for everything. At the other end of the spectrum are companies that only have only a few guidelines (only those required by the laws that are relevant to that company). Most companies fall somewhere in between these two extremes. The manager writing any guideline needs to understand where on the spectrum the company it falls and how the policy can be made to fit the organization s culture to enhance compliance. 24

26 Other two factors to be consider when developing guidelines and procedures are the fertilizer technology that company employs and local and international standards applicable to the industry. Internal standards and procedures must be developed in line with these factors, being applicable for your own plants and in line with regulatory requirements. The last, but not least, factor when developing your own procedures is the best industry practice that you need to employ. Liaison with your fertilizer association, participation in industry meetings and conferences and using fertilizer industry consultants can bring a fresh eye, new ideas and enhance the quality of your own guidelines and procedures. 13. DEFINITIONS AFD ALARP ATEX BoQ CCTV DCS ESD FEED FID FIORDA HAZID HAZOP HSE HV LOPA LV MAH MOC MTO MV NDT Approved for Design As Low As Reasonable Practicable Atmospheres Explosible Bill of Quantities Closed Circuit TV Distributed Control System Emergency Shut Down Front End Engineering Design Investment Decision Fertilizer Industry Operational Risks Database Hazard Identification Study Hazard and Operability Study Health Safety Environmental Health, Safety, Security and Environmental High Voltage Layer of Protection Analysis Low Voltage Major Accident Hazards of Change Material Take Off Medium Voltage Non-Destructive Test 25

27 SIL SIMOPS Safety Integrity Level Simultaneous Operational Studies Disclaimer The information contained in this document is given in good faith and while every care has been taken in preparing these documents, UreaKnowHow.com and AmmoniaKnowHow.com make no representations and give no warranties of whatever nature in respect of these documents, including but not limited to the accuracy or completeness of any information, facts and/or opinions contained therein. Both companies, its subsidiaries, the directors, employees and agents cannot be held liable for the use of and reliance of the opinions, estimates, forecasts and findings in these documents. 26

28 Fertilizer Industrial Services Ltd Venture House, Arlington Square Downshire Way, Bracknell, RG12 1WA, UK P: + 44 (0) Web: dan.cojocaru@fertilizer.services