PDRI for MLS - valencyinc.comvalencyinc.com/wp-content/uploads/2017/10/PDRI-for-MLS-Element... · 0...

0

PDRI for MLS Element Descriptions Version 1.2

Last Updated: September 28, 2017

1

Table of Contents

Revision History ......................................................................................................................... 4

Section I Basis of Project Decision .......................................................................................... 5

A. BUSINESS OBJECTIVES .................................................................................................... 5

A.1 Products & Services ....................................................................................................... 5

A.2 Market Strategy .............................................................................................................. 5

A.3 Project Objectives & Strategy ......................................................................................... 5

A.4 Project Philosophies ....................................................................................................... 6

A.5 Facility Portfolio Coordination ......................................................................................... 7

A.6 Affordability/Feasibility .................................................................................................... 7

A.7 Capacities ....................................................................................................................... 7

A.8 Future Expansion Considerations ................................................................................... 8

A.9 Expected Facility Life Cycle ............................................................................................ 8

A.10 Social Issues ................................................................................................................. 8

B. BASIC DATA RESEARCH & DEVELOPMENT ................................................................... 9

B.1 Technology ..................................................................................................................... 9

B.2 Processes ....................................................................................................................... 9

C. PROJECT SCOPE ............................................................................................................... 9

C.1 Project Design Criteria .................................................................................................... 9

C.2 Site Characteristics Available vs. Required .................................................................. 10

C.3 Dismantling and Demolition Requirements .................................................................. 11

C.4 Lead/Discipline Scope of Work ..................................................................................... 12

C.5 Project Funding ............................................................................................................ 12

D. VALUE ENGINEERING ..................................................................................................... 12

D.1 Process Simplification .................................................................................................. 12

D.2 Design & Material Alternatives Considered/Rejected ................................................... 13

D.3 Design for Constructability Analysis ............................................................................. 13

Section II Basis of Design ....................................................................................................... 14

E. Site Information .................................................................................................................. 14

E.1 Site Location ................................................................................................................. 14

2

E.2 Surveys & Soil Tests ..................................................................................................... 14

E.3 Environmental Assessment .......................................................................................... 15

E.4 Permit Requirements .................................................................................................... 15

E.5 Utility Sources with Supply Conditions ......................................................................... 16

E.6 Fire Protection & Safety Considerations ....................................................................... 16

F. PROCESS/MECHANICAL .................................................................................................. 17

F.1 Process Flow/Utility Flow Diagrams .............................................................................. 17

F.2 Heat & Material Balances or Process Modeling ............................................................ 17

F.3 Piping and Instrumentation Diagrams (P&IDs) ............................................................. 17

F.4 Air Flow and Instrumentation Diagrams (AF&IDs) ........................................................ 18

F.5 Process Safety Management (PSM) ............................................................................. 19

F.6 Process and Mechanical Specifications ........................................................................ 19

F.7 Piping System Requirements ........................................................................................ 20

F.8 Mechanical Equipment List ........................................................................................... 20

F.9 Line List / Tie-in List / Piping Specialty Items List ......................................................... 21

F. 10 Instrument Index ........................................................................................................ 22

F.11 Process & Mechanical Test Plan ................................................................................ 22

G. EQUIPMENT SCOPE ........................................................................................................ 23

G.1 Equipment Status ......................................................................................................... 23

G.2 Equipment Location Drawings ...................................................................................... 23

G.3 Equipment Utility Requirements ................................................................................... 23

H. Building Programming & Design Parameters ..................................................................... 24

H.1 Building Space Requirements ...................................................................................... 24

H.2 Site/Plot Plan ................................................................................................................ 25

H.3 Circulation and Open Space Requirements ................................................................. 25

H.4 Building Functional Programming ................................................................................. 25

H.5 Architectural Layouts, Sections & Elevations ............................................................... 26

H.6 Room Requirements Data ............................................................................................ 27

H.7 Loss Prevention Considerations ................................................................................... 27

H.8 Civil/Structural Requirements ....................................................................................... 28

H.9 Building Mechanical Design ......................................................................................... 28

3

H.10 Building Electrical Design ........................................................................................... 29

H.11 Building Life Safety Requirements ............................................................................. 30

H.12 IT/Telecom .................................................................................................................. 30

I. INFRASTRUCTURE ............................................................................................................ 31

I.1 Water Treatment Requirements ..................................................................................... 31

I.2 Loading/Unloading/Storage Facilities Requirements ..................................................... 31

I.3 Transportation Requirements ......................................................................................... 31

J. INSTRUMENT & ELECTRICAL .......................................................................................... 32

J.1 Electrical Area Classifications ....................................................................................... 32

J.2 Substation Requirements/Power Sources Identified ..................................................... 32

J.3 Electric Single Line Diagrams ....................................................................................... 33

J.4 Instrument & Electrical Specifications ........................................................................... 33

K. ENTERPRISE & CONTROL SYSTEMS ............................................................................ 34

K.1 Measurement and Final Control Devices ...................................................................... 34

K.2 Monitoring and Control Systems ................................................................................... 34

K.3 Manufacturing Operations Systems .............................................................................. 35

K.4 Business Planning and Logistics System ..................................................................... 35

Section III Execution Approach ............................................................................................... 36

L. PROCUREMENT STRATEGY ........................................................................................... 36

L.1 Identify Long Lead/Critical Equipment and Materials .................................................... 36

L.2 Procurement Procedures and Plans ............................................................................. 36

L.3 Procurement Responsibility Matrix ................................................................................ 37

M. DELIVERABLES ................................................................................................................ 38

M.1 CADD/Model Requirements ......................................................................................... 38

M.2 Deliverables Defined .................................................................................................... 38

M.3 Distribution Matrix......................................................................................................... 39

N. PROJECT CONTROLS ...................................................................................................... 39

N.1 Project Cost Estimate ................................................................................................... 39

N.2 Project Change Control ................................................................................................ 39

N.3 Project Cost Control ..................................................................................................... 40

N.4 Project Schedule Control .............................................................................................. 41

4

N.5 Progress Measurement ................................................................................................ 42

N.6 Risk Management ......................................................................................................... 43

P. PROJECT EXECUTION PLAN .......................................................................................... 43

P.1 Project Organization ..................................................................................................... 43

P.2 Owner Approval Requirements ..................................................................................... 44

P.3 Engineering & Construction Plan .................................................................................. 44

P.4 Shut Down/Turn-Around Requirements ........................................................................ 45

P.5 Commissioning/Qualification/Validation Plan ............................................................... 45

P.6 Startup & Turnover Requirements ................................................................................ 46

P.7 Training Requirements ................................................................................................. 47

P.8 Environmental & Safety Procedures ............................................................................. 47

Revision History Version Date PDRI Spreadsheet Version Date V1.1 July 26 V1-1 Sept 27 V1.2 Sept 28 V1-2 Sept 28

5

Section I Basis of Project Decision A. BUSINESS OBJECTIVES A.1 Products & Services A list of product(s) to be manufactured or services to be offered, along with specifications and tolerances that the project is intended to deliver. It should address items such as:

• Chemical composition • Physical form/properties • Raw material properties • Packaging • Intermediate/final product form • Allowable impurities • By-products • Wastes and emissions • Hazards associated with products • Services (e.g. fabrication, assembly, processing)

For projects that do not apply directly to products (e.g., instrument upgrade, environmental improvements, structural integrity, regulatory compliance, infrastructure improvement), this element should be considered not applicable.

A.2 Market Strategy A market strategy has been developed and clearly communicated. It identifies the business case and driving forces (other than safety) for the project and specifies what is most important from the viewpoint of the business group. It should address items such as:

• Growth, expansion, replacement, or internalization driven project • Cost:

o Maximum project cost that market will accept o Production cost o Cost reduction over time

• Schedule: o Product demand schedule (over operational life) o First product sales date

• Quality, including critical product specifications • Regulatory

A.3 Project Objectives & Strategy Project objectives and priorities for meeting the market strategy should be documented and shared. The relative priority among cost, schedule, and quality should be outlined. Key stakeholders (e.g., owner/operations, planners, environmental/permitting, design/engineering, procurement, construction, commissioning/startup, and external stakeholders) should be engaged to ensure the project is aligned to the applicable objectives and constraints at the portfolio, business unit and organization level. The following should be considered:

• Typical objectives: o Safety

6

o Security o Quality of product or quality of life o Cost o Schedule o Technology usage o Performance/capacity o Startup or commissioning o Communication o Operational performance o Maintainability/reliability o Environmental/sustainability

• Stakeholder’s understanding of the objectives, including questions or concerns answered

• Constraints or limitations placed on the project which if not addressed or overcome, could adversely affect the project’s ability to meet objectives

A.4 Project Philosophies General project design philosophies to meet the project objectives have been documented. Philosophies should define:

• Operating Philosophy (achieving the projected overall performance requirements such as on-stream time or service factor)

o Operating time sequence (e.g., ranging from continuous operation to five day, day shift only)

o Necessary level of segregation and clean out between batches or runs o Level of operator coverage and automatic control to be provided, aligned with

union operator contractual agreements o Desired unit turndown capability; design requirements for routine startup and

shutdown o Security protection for material management and product control o Achieving service quality/throughput

• Reliability Philosophy (achieving dependable operating performance) o Control, alarm, security and safety systems redundancy, and access control o Measures to be taken to prevent loss o Mechanical/structural integrity of components (e.g., metallurgy, seals, types of

couplings, bearing selection, corrosion allowance) o Installed spare equipment and strategic spares

• Maintenance Philosophy (meeting maintenance goals) o Scheduled unit/equipment shutdown frequencies and durations o Equipment access/monorails/cranes/pick points sized appropriately o Equipment monitoring requirements (e.g., lubricants, vibrations, infrared viewing

windows, oil-sampling ports) • Design Philosophy (related to building programming scope, if applicable)

o Asset life o Matching existing features and/or materials o Preservation efforts – cultural & architectural o Compatibility with master plan

7

o Environmentally sustainable design (internal/external) and level of certification o Compatibility with existing Design (e.g., equipment, egress)

Additional items to consider for Renovation & Revamp projects

• Align new project component’s lifecycle with existing systems/plant/process lifecycle • Maintenance requirements during renovation • Common/spare parts (repair vs. replace existing components) • Interruptions to existing and adjacent facilities and operations • Compatibility of maintenance philosophy for new systems and equipment with existing

use and maintenance philosophy • Coordination of the project with ongoing or planned maintenance projects

A.5 Facility Portfolio Coordination The project’s impact on the overall facility portfolio (or program) has been considered. Projects that are impacted by this project, as well as projects that may impact this one have been identified. Key considerations include:

• Identifying interfaces and dependencies • Schedule coordination • Key resource allocation (e.g., Subject Matter Experts, Site reps) • Project Manager coordination

A.6 Affordability/Feasibility Items that may improve the affordability of the project have been considered during options analysis and scope development. These items may include incremental cost criteria such as:

• Consideration of raw material availability and transport to the facility • Understanding of raw material and product variability in relation to cost and volume • Reduction in manufacturing costs • Performing an analysis of capital and operating cost versus sales and profitability • Long-term environmental sustainability considerations

A.7 Capacities The design output or benefits to be gained from this project should be documented. Capacities are usually defined in terms of:

• Overall Equipment Effectiveness (OEE) – availability, performance, quality • Yield • Design rate • Increase in storage, throughput or efficiencies • Regulatory driven requirements • Product quality improvement • Headcount

8

A.8 Future Expansion Considerations A list of items to be considered in the unit design that will facilitate future expansion should be developed. Evaluation criteria may include:

• Providing space for future equipment, phased development, or additional processing without compromising on-going operations, safety or security

• Technology considerations as the facility grows or changes (e.g., IT, communications, power, mechanical systems, water demands)

• Shell space (unfinished inside) • Providing additional land for future structures and parking, in alignment with site master

plan, taking into account zoning, easements, and yards. • Environmental considerations and impacts

A.9 Expected Facility Life Cycle The time period that the facility is expected to be able to satisfy the products or services and capacities required should be documented. The life cycle will affect the selection of critical equipment, materials and control devices. Requirements for ultimate disposal and dismantling should also be considered. Issues to consider may include:

• Operating life cycle (i.e., 10, 15, 20 years) o Manufacturing process o Facility

• Cost of ultimate dismantling and disposal • Disposal of hazardous materials • Possible future uses • Environmental sustainability considerations

A.10 Social Issues Identify and document any social issues, that if not addressed, could adversely impact the successful implementation of the project. These may include issues affecting the local or regional population. Evaluation of social issues may include:

• Domestic culture vs. international culture • Community relations • Labor relations • Government relations • Education/training • Safety and health considerations • Environmental assessment/sustainability

9

B. BASIC DATA RESEARCH & DEVELOPMENT B.1 Technology The technology(ies) being used in this project to gain the desired results should be identified. Technologies may include chemical, biological, mechanical processes, information technology, communication devices, imaging, single-use technology, or robotics. Proven technology involves less risk than experimental technology to project cost or schedule. Issues to evaluate when assessing technologies include:

• Existing/proven or replication • New • Experimental • Scale up from bench or pilot application to commercial scale • Organization’s experience with the process steps • Software development • Requirements for intellectual property protection


• Integration of new technology with existing systems, including interface issues • Safety systems that could potentially be compromised by a new technology

B.2 Processes A specific sequence of steps to change the raw materials, intermediates, or sub- assemblies into the finished product or outcome. These process steps may involve conversion of an existing process stream into a new sequence of steps to meet facility requirements. Proven sequences of steps involve the least risk, while experimental processes have a potential for change or problems. Issues to evaluate include:

• Existing/proven or replication • New • Experimental • Scale up from bench or pilot application to commercial scale • Organization’s experience with the process steps

C. PROJECT SCOPE C.1 Project Design Criteria The requirements and guidelines that govern the design of the project should be developed. When performing repetitive projects for the same facility, these may be well understood. Evaluation criteria may include:

• Level of design detail required • Climatic data • Codes and standards

o National o Local

10

• Utilization of engineering standards o Owner standards o Contractor standards o Mix of Owner and Contractor standards

• Security standards/guidelines to be utilized • Bio-hazard level • LEED certification • Health, safety and environmental regulations and/or standards


• Clearly define controlling specifications, especially where new codes and regulations will override older requirements

• Ensure that specifications support replacement of any obsolete systems or equipment C.2 Site Characteristics Available vs. Required An assessment of the available versus the required site characteristics is needed. The intent is to ensure that the project team has taken into consideration the need to improve or upgrade existing site development and support characteristics. Issues to consider should include:

• Capacity: o Utilities o Fire-protection water o Flare systems o Cooling water o Electrical power, including emergency backup o Pipe racks and arbors o Waste treatment/disposal o Process and chemical waste treatment/disposal o Storm water containment system o Type of buildings/structures o Parking o Land area

• Landscape (e.g., irrigation systems, vegetation) and hardscape (e.g., walkways, benches)

• Amenities: o Food service o Change rooms o Medical facilities o Recreation facilities o Ambulatory access

• Product shipping facilities • Maintenance facilities • Material receiving facilities • Material storage facilities • Product storage facilities • Security:

o Setbacks o Sight lines o Clear zones

11

o Access and egress o Fencing, gates and barriers o Security lighting

• Sustainability considerations, including possible certification (for example, by the U.S. Green Building Council).


• Complete condition assessment of existing facilities and infrastructure • As-built accuracy and availability (update/verify as-built documentation prior to project

initiation) • Past land use (potential contamination, structural issues) • Worksite availability and access for renovation and revamp activities • Existing space available to occupants during renovation work • Uncertainty of “as-found” conditions, especially related to: • Structural integrity: steel or concrete loading • Piping capacity/ integrity/ routing • Condition of required isolation points • Location, condition and capacity of electrical systems components • Investigation tools to assist in the documentation of existing conditions: • Photographs/Video • Remote inspection • Laser scanning • Infrared scanning • Non-Destructive Testing • Ground Penetrating Radar • Ultrasonic Testing

C.3 Dismantling and Demolition Requirements A scope of work has been defined and documented for the decommissioning and dismantling of existing equipment and/or piping which may be necessary for completing new construction or repurposing of the facility. This scope of work should support an estimate for cost and schedule. Evaluation criteria should include:

• Timing/sequencing • Intended re-use of the facility • Permits • Approval • Safety requirements • Hazardous operations and/or materials and any special contained demolition • Recycling of materials • Plant/operations requirements • Storage or disposal of dismantled equipment/materials • Narrative (scope of work) for each system • Environmental assessment • Are the systems that will be decommissioned/dismantled:

o Named and marked on process flow diagrams o Named and marked on P&IDs o Denoted on line lists and equipment lists o Denoted on piping plans or photo-drawings

12


• Use of photographs, video records, etc. in scope documents to ensure existing conditions clearly defined

• Physical identification of extent of demolition to clearly define limits • Segregation of demolition activities from new construction and operations (e.g., physical

disconnect or “air gap”) • Establish decontamination and purge requirements to support dismantling

C.4 Lead/Discipline Scope of Work A complete narrative description of the project laying out the major components of work to be accomplished, generally discipline oriented, should be developed. This narrative should be tied to a high-level Work Breakdown Structure (WBS) for the project. Items to consider would include:

• Sequencing of work • Interface issues for various contractors, contracts, or work packages


• Identification of specific interface or coordination efforts with operations and owner’s staff

C.5 Project Funding Funding requirements and approval process have been identified and documented. These requirements will form the basis of estimate and schedule to be developed. Items to consider include:

• Alignment with funding of related projects, programs and the overall portfolio • Initial project cost estimates (e.g., engineering, construction, land, equipment, operating

costs) • Comparison of funding options • Comparison of cost estimate with similar projects or benchmarks • Alignment of funding participants on approval schedule, cash flow, spend plan, cost

drivers,andcontingencies Detailed cost estimate requirements are addressed in N.1 Project Cost Estimate.

D. VALUE ENGINEERING D.1 Process Simplification A structured value analysis approach should be in place to identify and document activities or strategies (through studies, reviews) for reducing the number of steps or the amount of equipment needed in the process in order to optimize performance without compromising safety and security. Items to evaluate include:

• Redundancies • Over capacity • Discretionary spares • Excessive controls

13

D.2 Design & Material Alternatives Considered/Rejected A structured approach is in place to consider design and material alternatives including sustainability considerations. Specific activities have been identified to ensure that this process will take place.

Items that impact the economic viability of the project should be considered. Items to evaluate include issues such as:

• Discretionary scope issues • Expensive materials of construction • Life-cycle analysis of construction methods

D.3 Design for Constructability Analysis A structured process is in place for constructability analysis. CII defines constructability as, “the optimum use of construction knowledge and experience in planning, design, procurement and field operations to achieve overall project objectives. Maximum benefits occur when people with construction knowledge and experience become involved at the very beginning of a project.”

Provisions have been made to provide this on an ongoing basis. This process includes examining design options that minimize construction costs while maintaining standards of safety, security, quality and schedule. This process should be initiated in the front end planning process during concept or detailed scope definition. Elements of constructability during front end planning include:

• Constructability program in existence • Construction knowledge/experience used in project planning • Early construction involvement in contracting strategy development • Developing a construction-sensitive project schedule (with operations input and

considering operational needs) • Considering major construction methods in basic design approaches • Developing site layouts for efficient construction • Early identification of project team participants for constructability analysis • Usage of advanced information technologies


• Installability (e.g., smaller components/modules/pre-assembly to facilitate installation in congested areas)

• Opportunities to perform as much work as possible outside of shutdowns or outages • Developing an operations-sensitive project schedule (e.g., minimization of

Shutdown/Turnaround work and hot work in operating areas)

14

Section II Basis of Design E. Site Information E.1 Site Location The geographical location(s) of the proposed project has been defined and documented. This involves an assessment of the relative strengths and weaknesses of alternate site locations. A site that meets owner requirements and maximizes benefits for the owner company should be selected. Evaluation of sites may address issues relative to different types of sites (i.e., global country, local, “inside the fence,” or “inside the building”). This decision should consider the long-term needs of the owner company. The selection criteria should include items such as:

• General geographic location o Access to the targeted market area o Near sources of raw materials o Local availability and cost of skilled labor (e.g., construction, operation) o Available utilities o Existing facilities

• Land availability and costs • Environmental/sustainability impact • Access (e.g., road, rail, marine, air) • Construction access and feasibility • Security constraints (consider potential security breach points, e.g., storm water system,

watercourses) • Political constraints • Legal constraints • Regulatory constraints • Financing requirements • Social issues • Weather • Climate


• Change in intended use of the facility • Zoning, permitting or other regulatory changes brought about by R&R

E.2 Surveys & Soil Tests Survey and soil test evaluations of the proposed site should be developed and include items such as:

• Topography map • Overall plant plot plan • General site description (e.g., terrain, existing structures, spoil removal, areas of

hazardous waste) • Definition of final site elevation • Benchmark (coordinate and elevation) control system identified • Spoil area (i.e., location of on-site area or off-site instructions) • Seismic requirements

15

• Water table • Soil percolation rate & conductivity • Existing contamination • Ground water flow rates and directions • Downstream uses of ground water • Need for soil treatment or replacement • Description of foundation types • Allowable bearing capacities • Pier/pile capacities

E.3 Environmental Assessment An environmental assessment should be performed for the site to evaluate issues that can impact the cost estimate or delay the project. These issues may include characteristics such as:

• Location in an air quality non-compliance zone (such as identified by the U.S. Environmental Protection Agency (EPA) or others)

• Location in a wetlands area • Environmental permits now in force • Location of nearest residential area • Ground water monitoring in place • Containment requirements • Existing environmental problems with the site such as:

o Asbestos/PCB § Radioactive materials

o Contaminated soils § Lead or other heavy metal (e.g., Chromium, Mercury) § Hazardous or toxic chemical/biological contamination

• Past/present use of site • Sustainability • Archeological • Endangered species • Erosion/sediment control

E.4 Permit Requirements A permitting plan for the project should be in place. The permitting plan should identify design input requirements, and the effect each permit may have on the design plan. The local, state or province and federal government permits necessary to construct and operate the unit/facility should be identified, and include items such as:

• Construction • Local • Environmental • Transportation • Coastal Development • Security • Fire

16

• Building • Occupancy • Railroad • Levee board • Highway


• Original intent of codes and regulations and any “grandfathered” requirements

E.5 Utility Sources with Supply Conditions A list has been made identifying availability/non-availability or redundancy of offsite/onsite utilities needed to operate the unit/facility. This list includes supply conditions such as temperature, pressure and quality. Items to consider include:

• Potable water • Drinking water • Cooling water • Fire water • Sewers • Power (voltage levels) • Instrument air • Plant air • Gases • Steam • Condensate

E.6 Fire Protection & Safety Considerations A list of fire and safety related items to be taken into account in the design of the facility should include fire protection practices at the site, available firewater supply (amounts and conditions), special safety and security requirements unique to the site. Evaluation criteria should include:

• Eye wash stations • Safety showers • Fire monitors & hydrants • Foam • Evacuation plan • Perimeter security • Deluge requirements • Wind direction indicator devices (i.e., wind socks) • Alarm systems • Medical facilities


• Interruption to any existing fire and life safety systems

17

• Disarming existing safety systems for renovation work (with appropriate contingency planning)

F. PROCESS/MECHANICAL F.1 Process Flow/Utility Flow Diagrams Drawings that provide the process description of the unit/facility should be developed. Evaluation criteria should include:

• Major equipment items • Flow of materials to and from the major equipment items • Sufficient information to allow sizing of all process lines • Wash-in Place, Clean-in Place, Sanitize-in Place for process equipment • Process-utility generation equipment:

o Steam (clean/pure) o Process water (water for injection, purified water, filtered water, deionized water,

laboratory water, etc.) • Gas generation (oxygen, nitrogen, carbon dioxide, etc.) • Definition of Technology (single-use versus fixed equipment)


• Definition of owner’s requirements for updating existing process flow sheets.

F.2 Heat & Material Balances or Process Modeling Heat balances are tables of heat input and output for major equipment items (including all heat exchangers) within the unit. Material balances are tables of material input and output for all equipment items within the unit. The documentation of these balances should include:

• Special heat balance tables for reaction systems • Information on the conditions (e.g., temperature and pressure) • Volumetric amount (e.g., gallons per minute (GPM), liters per second (LPS), cubic feet

per minute (CFM)) or mass flow rates (e.g., kilogram per hour (kg/hr))


• Definition of owner’s requirements for updating existing heat and material balances.

F.3 Piping and Instrumentation Diagrams (P&IDs) These may be referred to by different companies as:

• EFDs – Engineering Flow Diagrams • MFDs – Mechanical Flow Diagrams • PMCDs – Process & Mechanical Control Diagrams

In general, P&IDs are considered to be a critical element within the scope definition package of an industrial project. P&IDs should address the following areas:

• System Number • Equipment

18

• Piping • Valves • Piping specialty items • Utilities • Tie-Points • Instrumentation • Safety systems

o Relief Device Calculations o Relief Device Sizing o Emergency Response Systems

• Special notations Additional items to consider for Renovation & Revamp projects

• Accuracy of existing P&ID’s (field verify) • Scope of Work on existing P&IDs (clouding or shading to indicate: new, refurbished,

modified, and/or relocated equipment, piping, instruments and controls).

Since incomplete information on P&IDs is frequently identified as a source of project escalation, it is important to understand their level of completeness. It is unlikely for P&IDs to be completely defined in a project’s scope definition package. However, the P&IDs must be complete enough to support the accuracy of estimate required. P&IDs are traditionally completed in the following iterations or “issues”:

• Preliminary issue – comment and work input from other disciplines and the owner’s representatives

• Issue for approval – critical information is complete, including lines sized, specifications developed, equipment identified and blocks complete for owner approval

• Issue for design – all owner comments have been incorporated and P&IDs are ready for the appropriate level of process safety management (PSM) review

• Issue as basis of estimate—all of process safety review has been completed and all comments incorporated

F.4 Air Flow and Instrumentation Diagrams (AF&IDs) AF&IDs are similar to P&IDs in that they show all ductwork from generation to return and/or exhaust points. AF&ID are evaluated using the same criteria as P&IDs, including these:

• HVAC area classification drawings. • HVAC zone-map drawings. • Terminal HEPA-filter plan drawings. • Differential-pressure plan drawings. • Integration of HVAC/BMS/CSV processes


• Tie-in points • Accuracy of existing AF&ID’s (field verify)

19

• Scope of Work on existing AF&IDs (clouding or shading to indicate: new, refurbished, modified, and/or relocated equipment, duct work, instruments and controls).

F.5 Process Safety Management (PSM) This element refers to a formal Process Safety Management Hazards Analysis to identify potential risk of injury to the environment or populace. Each national government (or organization) will have its specific PSM compliance requirements. (for example, in the U.S., OSHA Regulation 1910.119 compliance is required). The important issue is whether the owner has clearly communicated the requirements, methodology and responsibility for the various activities. If the PSM has not been conducted, the team should consider the potential of risk that could affect the schedule and cost of the project.

These questions should generally be asked: • Has the Owner identified all applicable jurisdictional PSM requirements and clearly

communicated the requirements, methodology, and responsibility for the various activities?

• Have all applicable organizational requirements been identified, communicated, and resourced?

• Has a project evaluation been done to determine if hazards are present or if the project involves installation of a high-energy process or significant changes to a high-energy process and applicability?

• If combustible dust is present have all applicable regulations and requirements been identified, communicated and resourced? Have PSM and combustible-dust requirements been identified and resourced?

• Have the use of any flammables been identified and designed for?

F.6 Process and Mechanical Specifications General specifications for the design, performance, manufacturing, material and code requirements should be documented. These specifications should include items such as:

• Classes of equipment (e.g., pumps, exchangers, vessels) • Process pipe heating

o Process o Freeze o Jacketed

• Process pipe cooling o Jacketed o Traced

• Piping • Protective coating • Insulation • Valves • Bolts/gaskets


• Reconciliation of original specifications with current project specifications

20

F.7 Piping System Requirements Piping system stress guidelines and requirements should be provided to ensure that piping system design can be estimated and scheduled. The owner must communicate the standards, methodology and record documentation required to support the piping systems design effort. Criteria for design of piping systems should include:

• Allowable forces and moments on equipment • Graphical representation of piping line sizes that require analysis based on:

o Temperature o Pressure o Cyclic conditions o Flex o Stress o Pulsation o Seismic


• Verification of existing conditions: hangers, supports, anchors, wall thickness, etc • Field verify existing lines that will be modified and requiring stress analysis back to all

anchor points • Ensure lines are functioning, available and active

F.8 Mechanical Equipment List The mechanical equipment list should identify all mechanical equipment by tag number, in summary format, to support the project. The list should define items such as:

• Existing Assets: o Modified o Relocated o Dismantled o Re-rated

• New Assets: o Purchased new o Purchased used

• Relative sizes • Weights • Location • Capacities • Materials • Power requirements • Flow diagrams • Design temperature and pressure • Insulation & painting requirements • Equipment related ladders and platforms

21

F.9 Line List / Tie-in List / Piping Specialty Items List The line List / Tie-in List / Piping Specialty Items List designates all pipe lines in the project (including utilities), piping tie-ins to existing lines should be developed, in-line piping items not covered by piping material specifications.

All lists should include such items such as:

• Reference drawing • Piping Specifications

The Line List should include items such as:

• System/Line numbers • Size • Termination • Origin • Design temperature and pressure • Testing requirements • Insulation/Paint requirements

The Tie-in List should include items such as:

• Location • Insulation removal requirements • Decontamination requirements • Timing/schedule • Type of tie-in/size

The Specialty Item List should include items such as:

• System / Tag numbers • Quantities • Piping plans referenced • Piping details • Full purchase description • Line/equipment numbers


• Field verify condition of isolation points • Sequencing of tie-ins with production planning requirements to ensure safety and on-

going operations • Establish decontamination and purge requirements to support tie-ins • Tie-in locations approved by Operations • Ensure and conduct a structured process to validate tie-ins and tie-in strategy.

22

F. 10 Instrument Index This is a complete listing of all instruments by tag number. Evaluation criteria should include:

• System / Tag number • Instrument type • Service • P&ID number • Line number • Insulation, paint, heat tracing, winterization, etc. requirements • Relieving devices (e.g., relief valves, rupture disks)


• Instrument status (e.g., new, existing, relocate, modify, refurbish, or dismantle) • Existing instrumentation and valves (trim, functionality, leakage, closure, etc.)

F.11 Process & Mechanical Test Plan A robust Factory Acceptance Testing (FAT) / Site Acceptance Testing (SAT) plan for the delivery of equipment is required to ensure issues are resolved at the factory and not transferred to the project site. Items to address in the plan include:

• Strategy for automation support of FAT tests (e.g., PLC, temporary DCS) • Configuration Test Plan for FAT/System Integration Testing (SIT)/SAT including

simulation requirements • Validation Test Plan for FAT/SIT/SAT • Critical tests (e.g., vibration, resonance, regression testing) • Hardware FAT procedure • Responsibility matrix clearly defining roles and responsibilities • Required training for vendors on FAT/SAT requirements • Example system turnover package (TOP) to share with vendors • Presence of utilities for FAT testing at vendor site. • Integration of Computer System Validation (CSV) and Commissioning & Qualification

(C&Q) activities. • FAT visits integrated with project schedule. • Travel and materials costs for testing

23

G. EQUIPMENT SCOPE G.1 Equipment Status Has the equipment been defined, inquired, bid tabbed, or purchased? This includes all engineered equipment such as:

• Process • Electrical • Mechanical • Heating, ventilation, air conditioning (HVAC) • Instruments • Security-related equipment • Specialty items • Distributed control systems

Evaluation criteria should include:

• Equipment data sheets • Number of items inquired • Number of items with approved bid tabs • Number of items purchased


• Modifications and refurbishment of existing equipment

G.2 Equipment Location Drawings Equipment location/arrangement drawings identify the specific location of each item of equipment in a project. These drawings should identify items such as:

• Elevation views of equipment and platforms • Top of steel for platforms and pipe racks • Paving and foundation elevations • Coordinates of all equipment


• Clearly identify existing equipment to be removed or rearranged, or to remain in place

G.3 Equipment Utility Requirements A tabulated list of utility requirements for all equipment items should be developed. This list should identify requirements such as:

• Air o Plant air o Instrument air o Vacuum system

• Water o Plant water

24

o Chilled water o Hot water o Process water (e.g., carbon filtered, degasified, demineralized)

• Steam o High pressure o Condensate system

• Fuel o Natural gas o Fuel oil o Propane o Alternatives

• Ventilation o HVAC o Refrigeration

• Process

H. Building Programming & Design Parameters H.1 Building Space Requirements Building space requirements should correspond to each space identified for the entire project.

Very early in FEL 3 (Basic Design), space requirements must be finalized on a detailed room-by-room basis. These requirements will be integrated into the Basic Design building functional programming efforts, which will enable building layouts to be completed. The requirements list should address specific types and areas and may include:

• Unclassified production, storage or technical areas (e.g., utilities, IT) • Classified (air, cleanliness, safety, security) production, storage or technical areas • General building services (e.g., loading docks, cafeteria) • Administrative areas (e.g., offices, classrooms, lounges, conference rooms, entry lobby,

washrooms, janitorial closets) • Laboratories • Elevators, stairs, corridors • Inter-modal transportation area

The goal is to identify all space requirements at a sufficient level of detail to prepare cost estimates using unit costs. Future expansion or requirements for change in use should be addressed for each building space.

25

H.2 Site/Plot Plan Site and plot plan drawings need to be developed and defined with consideration for all factors affecting operations within the new or existing facility. Considerations may include:

• Space requirements and configuration for o primary outdoor and building facilities, including processing, raw materials and

intermediate/final product storage o servicing facilities, including maintenance shops, utility buildings, security

buildings, onsite leased process gas facilities, truck scales, etc. • Traffic logistics, both within the new or existing facility, including parking and unloading

areas, vehicle delivery and pick-up logistics, etc. • Temporary facilities (e.g., construction/fabrication/laydown areas) • Site considerations dealing with

o neighboring plant operations o affected off-property neighbors and community relationships

• Site spill containment and storm drainage requirements • Site security requirements such as gates, fences and/or barriers • Future expansion planning / Master Planning

H.3 Circulation and Open Space Requirements The integration of the interior building requirements with exterior circulation and open space requirements must be suitably defined.

Very early in FEL 3 (Basic Design), these requirements must be fully defined so that architects can ensure the building functional programming efforts take them into account.

Requirements to consider may include:

• Service dock areas and access • Circulation to parking areas, parking spaces • Passenger drop-off areas and bus stops, bicycle facilities • Pedestrian walkways, sheltered walkways, outdoor patios and shelters • Landscape buffer areas, ponds • Unbuildable areas (e.g., wetlands or slopes) • Entry • Security considerations (e.g., card access or transmitters) • Snow removal plan • Postal and newspaper delivery • Waste removal • Fire and life-safety circulation considerations

H.4 Building Functional Programming Building functional programming is carried out by defining all special areas and the required flows amongst them. This is accomplished by various methods including:

• Adjacency Diagrams. These diagrams define the required inter-relationships of rooms and spaces within each department or division of an entire building. They are sometimes

26

used to represent the spatial requirements for various areas across a given site. They show the relationship of specific rooms, offices and sections. The adjacency diagrams must adequately convey the overall relationships between functional areas within the facility. Note that these diagrams are sometimes known as “bubble diagrams” or “balloon diagrams”, with each bubble representing a room with its space requirement, and arrows indicating flows of personnel, raw materials, intermediate and final products, and, ideally, HVAC, utilities, and process piping runs between the rooms. Critical transit times may be shown as well. They are also commonly expressed in an adjacency matrix. Anti-terrorism standards, building and perimeter security should also be shown on adjacency diagrams to ensure that configuration and setback distances are documented.

• Stacking Diagrams. These diagrams may be required to clarify requirements for spaces or processes to be vertically integrated (“stacked”) in a specific manner. A stacking diagram portrays each department or functional unit vertically in a multi-story building. Stacking diagrams are drawn to scale and they can help establish key design elements for the building. These diagrams are easily created with space lists and Adjacency Diagrams. Critical vertical relationships may relate to circulatory (stairs, elevators), structural elements and mechanical or utility shafts. Stacking diagrams can establish building elements such as floor size. This type of diagram often combines functional adjacencies and space requirements and also shows how the project is sited.

These diagrams are typically started early in FEL 3 (Basic Design), and serve as input to the final architectural layout effort (See item H.5).

H.5 Architectural Layouts, Sections & Elevations Architectural Layouts (or “Floor Plans”) represent the optimal design solution integrating all the building programming requirements into a dimensional plan. Layouts contain room number designations to which room requirements data can be linked. Architectural Layouts may include:

• Equipment arrangement plans • Floor plans • Reflected ceiling plans • Roof plans • Fire and life-safety plans • GMP Flow Diagrams

o Personnel flow o Material (raw and final product) flow o Equipment flow o Waste flow

Vertical building sections and elevations are produced to enable project teams to visualize the buildings inner workings in a manner that expedites review and finalization. Architectural Sections and Elevations may include:

• Floor elevations • Ceiling heights • Major equipment, materials, walls, doors, windows, louvers, etc.

27

Building Layouts, Sections, and Elevations define the basic design of the building to be implemented, and communicate the approved arrangement to detailed designers at the start of the execution phase of the project. Architectural layouts, sections and elevations are typically started early in FEL 3 (Basic Design), and completed by the end of the phase.

H.6 Room Requirements Data Room requirements data, in the form of a general specification or room-specific data sheets, contain the specific requirements for each room and consider its functional needs. Room requirements data should correspond to each room identified in the building space requirements. The format of the room requirements data should be consistent. Possible items include:

• Critical dimensions • Technical requirements (e.g., fireproof, explosion resistance, X-ray, containment or

isolation requirements) • Furnishing requirements • Equipment requirements • Finish types • Special door hardware requirements • Environmental issues, room air • Pressurization / Heating, ventilation and air conditioning (HVAC) classification

requirements • Audio/visual (A/V) data and communication provisions • Lighting requirements • Utility requirements • Security needs including access/hours of operations, controlled access requirements • Acoustics/vibration requirements • Life-safety

During detailed design, room requirements data will be expanded to indicate specific details of materials to be used in each individual room.

H.7 Loss Prevention Considerations Consideration of facility risk factors which are relevant to potential property loss, business interruption loss, or personnel injury must be identified to provide a facility design that is both compliant with statutory regulations, and optimally coordinated with insurer underwriter requirements and coverage options. Project design should include considerations to ensure that values of buildings/production capability do not exceed the risk management loss tolerance. Actions need to have been taken to have identified, investigated, and assessed all possible loss risks vs. regulatory requirements, including obtaining feedback from permitting authorities regarding critical issues.

28

Feedback of options from, and alignment with, the insurance underwriter needs to have been solicited, discussed, decided, and integrated into programming and design requirements and work products. H.8 Civil/Structural Requirements Civil/structural requirements need to be defined and should include:

• Basis of design loads – dead loads, live loads, snow loads, wind loads, seismic, etc. • Design requirements to be used including code requirements, safety factors,

construction materials. • Structural drawings • Pipe racks / supports • Elevation views, platform top-of-steel elevations • High-point elevations for grade, paving, and foundations • Location of heavy equipment and offices • Critical serviceability requirements, such as allowable vibrations, deflection control,

future heavy equipment in/out loads, material handling, etc. • Monorails or pick points, and tie-off points • Removable panels in buildings for large equipment in/out during future recapitalizations. • Critical minimum clearances, including material handling equipment • Fireproofing requirements, both materials used and extent of use • Corrosion-control requirements and required protective coatings • Waterproofing and damp proofing of structures, facades, slabs • Enclosure requirements (e.g., open, closed, covered, etc.) • Secondary containment • Dikes, including hydrostatic and uplift loads • Storm sewers • Methodology to account for thermal expansion in structures.

H.9 Building Mechanical Design Mechanical design parameters should be defined to provide a basis for facility programming and design. Items to consider include:

• Special ventilation or exhaust requirements • Equipment/space special requirements with respect to environmental conditions (e.g., air

quality, special temperatures) • Energy conservation and life cycle costs • Acoustical requirements • Zoning and controls • Air circulation requirements • Outdoor design conditions (e.g., minimum and maximum yearly temperatures) • Indoor design conditions (e.g., temperature, humidity, pressure, air quality) • Building emissions control • Utility support requirements • System redundancy requirements

29

• Plumbing requirements • Special piping requirements • Seismic requirements • Fire protection systems requirements • Environmentally-friendly heating, ventilation and air conditioning (HVAC) systems • Alternate energy systems


• Consider how renovation project alters existing mechanical design assumptions • Potential reuse of existing equipment and systems for renovation project

H.10 Building Electrical Design Electrical design parameters provide the basis for facility design. Items to consider include:

• Power sources with available voltage/amperage • Special lighting considerations (e.g., lighting levels, color rendition) • Voice, data and video communications requirements • Uninterruptable power source (UPS) and/or emergency power requirements • Energy consumption/conservation and life cycle cost • Ability to use daylight in lighting • Seismic requirements • Lightning/grounding requirements • Outdoor lighting requirements • Electrical classification requirements (e.g., spark, explosion proof) • Arc flash requirements


• Consider how renovation project alters existing electrical design assumptions • Potential reuse of existing equipment and systems for renovation project

30

H.11 Building Life Safety Requirements Building life safety requirements need to be defined. Safety requirements to consider include:

• Automation and hardware requirements o Fire-alarm system (detection and/or suppression requirements) o Access-control system o Closed circuit television systems

• Fire resistant requirements o Firewalls o Maximum foreseeable loss walls

• Explosion resistant requirements • Eye wash stations, safety showers • Deluge requirements and foam • Fume hoods • Handling of hazardous materials and waste • Isolation for spill and firewater containment inside or outside the facility • Sterile environments • Emergency equipment access • Personnel shelters in case of catastrophe, rally points and Shelter-in-place provisions • Egress • Public address requirements • Data or communications protection in case of disaster or emergency • Fall hazard protection • Gas hazard detection • Clearances for equipment access

H.12 IT/Telecom IT and telecom requirements need to be defined so that the building functional programming and layout efforts account for the spaces required for equipment. The associated requirements for heating, cooling, power supply (normal, emergency and UPS), fire suppression, static control and ceiling penetrations should also be defined. Items to consider include:

• Networking (wired, wireless) • Computers, printers and phones • Multimedia (e.g., digital signage, screens/monitors) • Mobility and video (e.g., video conferencing, RFID) • Backup philosophy (on-site or off-site and degree of backup required) • Server room • Telecom room

31

I. INFRASTRUCTURE I.1 Water Treatment Requirements Water treatment requirements should be documented. Items for consideration should include:

• Wastewater treatment: o Process waste o Sanitary waste

• Waste disposal • Storm water containment and treatment

I.2 Loading/Unloading/Storage Facilities Requirements A list of requirements identifying raw materials to be unloaded and stored, products to be loaded along with their specifications and Material Safety Data Sheets. This list should include items such as:

• Instantaneous and overall loading/unloading rates • Details on supply and/or receipt of containers and vessels • Storage facilities to be provided and/or utilized • Specification of any required special isolation provisions:

o Double wall diking and drainage o Emergency detection (e.g., hydrocarbon detectors/alarms) o Leak detection devices or alarms

• Essential security considerations should include: o Inspection requirements o Secure storage o Authorized deliveries o Access/egress control


• Availability and access to secure storage for materials, laydown yards, etc. for R&R projects

I.3 Transportation Requirements Specifications identifying implementation of “in-plant” transportation (e.g., roadways, concrete, asphalt, rock) as well as methods for receiving/shipping/storage of materials (e.g., rail, truck, marine) should be documented. Specifically look at detailed traffic/routing plan for oversize loads. Additional items to consider for Renovation & Revamp projects

• Coordinate equipment and material movement for renovation work with Operations to ensure no unplanned impacts

• Clearly identify delivery gates/ docks/ doors and receiving hours to be used by contractors for renovation and revamp work

32

J. INSTRUMENT & ELECTRICAL

J.1 Electrical Area Classifications The electrical area classification plot plan is provided to show the environment in which electrical and instrument equipment is to be installed. This area classification will follow the guidelines as set forth in the latest code requirements (for example, the National Electric Code in the U.S.). Installation locations should include the following:

• General purpose • Hazardous • Class I: Gasses and vapors • Class II: Combustible dusts • Class III: Easily ignitable fibers • Corrosive locations


• Reclassification impact on existing access and operating areas

J.2 Substation Requirements/Power Sources Identified Substation requirements should be documented and may include the following:

• Number of substations required • Electrical equipment rating required for each substation • Specifications for all major electrical substation equipment • Infrastructure required for each substation considering building type and

environment, fencing, access, lighting and barriers and substation yard materials • Clearly define power sources for the project in relation to:

o Location, voltage level, available power o Electrical equipment available o Electrical ratings and routes of power feeds from their sources to the project

substations o Specifications for special power sources should be described and provided (e.g.,

emergency generators or in-plant generation) o Temporary construction power sources


• Impact on existing equipment and new equipment selection (e.g., short circuit ratings)

• Field verify condition of isolation points • Sequencing of tie-ins with production planning requirements to ensure safety and on-

going operations • Tie-in points approved by Operations • Ensure and conduct a structured process to validate tie ins and tie-in strategy. • Ensure that new electrical systems or equipment are compatible with industrial

environment (e.g., uninterrupted power supplies, inverters, etc.)

33

J.3 Electric Single Line Diagrams A single line diagram indicates the components, devices, or parts of an electrical power distribution system. Single line diagrams are intended to portray the major system layout from the public utility’s incoming transmission line to the motor starter bus. Depending on the size of the electrical system, the single line diagrams should include several levels of distribution such as:

• Incoming utility with owner substation/distribution to high and medium voltage motors and substations

• Unit substations and switchgear • Motor control centers with distribution to motors, lighting panels

J.4 Instrument & Electrical Specifications Specifications for instrument and electrical systems should be developed and should include items such as:

• Distributed Control System (DCS) • Instrument data sheets • Motor control and transformers • Power and control components • Power and control wiring (splicing requirements) • Cathodic protection • Lightning protection • Security systems • Grounding • Electrical trace • Installation standards • Lighting standards • Civil requirements for electrical installation:

o Protection/warning for underground cabling o Special slabs or foundations for electrical equipment o Concrete-embedded conduit

34

K. ENTERPRISE & CONTROL SYSTEMS K.1 Measurement and Final Control Devices Technology requirements should be defined for the sensing and manipulation of the physical manufacturing processes. Details of the asset management strategy that the devices must support, and the required process and device information to integrate with the monitoring and control systems should be documented. Considerations include:

• Measurement instrumentation • Valves, actuators, and regulators including position measurement (limit switches, etc.) • Input/Output (I/O) technology including considerations such as wired, serial, HART,

digital buses and wireless • I/O wiring strategy including considerations such as remote I/O (in the field) and

electronic marshalling (hardwired or software) • Analyzer requirements • Asset monitoring including the health of field devices, pipelines and machinery • Quality and validation Requirements

Additional items to consider for Renovation and Revamp projects

• Reconciliation and compatibility of the existing instrumentation, valves, system components and wiring

• I/O cutover strategy such as hot vs. cold

K.2 Monitoring and Control Systems Monitoring and control system requirements should be documented. Important considerations include:

• System architecture • On/Off control • Continuous control • Interlock and safety control • Operator control • Operator visibility • Alarm management • Supervisory control • Phase control • Recipe control • Data historian and reports • Simulation requirements • Integration with modular/skid mounted monitoring and control systems • Integration with the manufacturing operations systems • Cyber security requirements • Operator training requirements • Validation requirements


• Existing system reverse engineering design methodology • Execution methodology (phased vs all at once)

35

• Integration with existing control systems • Status of existing documentation

K.3 Manufacturing Operations Systems The work flow requirements for the product(s) to be manufactured should be documented. Important considerations include:

• Production operations management • Maintenance operations management • Laboratory (quality) operations management • Materials handling & storage (inventory) operations management • Production reporting requirements • Integration with business planning and logistics systems


• Impact to existing manufacturing operations systems

K.4 Business Planning and Logistics System The business-related activity requirements that must be managed by manufacturing systems should be defined. Important considerations include:

• Plant production scheduling • Inventory management • Management of shipments in and out of the facility • Regulatory requirements


• Impact to existing business logistics systems

36

Section III Execution Approach L. PROCUREMENT STRATEGY L.1 Identify Long Lead/Critical Equipment and Materials Identify engineered equipment and material items with lead times that will impact the detailed engineering for receipt of vendor information or impact the construction schedule with long delivery times. Additional items to consider for Renovation & Revamp projects Identification and delivery of long lead/critical equipment and materials are especially important for shutdowns/turnarounds.

• Delivery dates must be identified in advance of shutdown/turnarounds to support preparations for pre-outage activities

L.2 Procurement Procedures and Plans Specific guidelines, special requirements, or methodologies for accomplishing the purchasing, expediting, delivery and security of equipment and materials required for the project. Evaluation criteria should include:

• Listing of approved vendors • Client or contractor paper • Reimbursement terms and conditions • Contract payment terms (e.g., lump-sum, cost-plus fee, cost-plus a fee with a

guaranteed maximum price (GMP)) • Guidelines for supplier alliances, single source, or competitive bids • Guidelines for engineered/field contracts • Responsibility for owner-purchased items:

o Financial o Shop inspection o Expediting

• Tax strategy: o Engineered equipment o Field materials o Labor o Write-offs of existing facilities and equipment

• Definition of source inspection requirements and responsibilities • Definition of traffic/insurance responsibilities • Definition of procurement status reporting requirements • Additional/special owner accounting requirements • Definition of spare parts requirements, including consideration to match existing • Local regulations (e.g., tax restrictions, tax advantages)


• Procedures for repair, refurbishment and relocation of existing equipment • Retrofit kits (e.g., non-standard connections and obsolete equipment may require

adaptors)

37

L.3 Procurement Responsibility Matrix A procurement responsibility matrix has been developed showing authority and responsibility for procurement. This matrix should outline responsibilities for:

• Engineering and design • Engineered equipment • Construction • Bulk materials • Fabrication/modularization • Consulting services • Commissioning and startup materials • Source inspection


• Utilization of reused and existing equipment, materials, lines, electrical and instrumentation, etc.

• Availability of procurement support during time constrained R&R work, especially where expedited material services are required

38

M. DELIVERABLES M.1 CADD/Model Requirements Computer Aided Drafting and Design (CADD) and Building Information Model (BIM) requirements should be defined. Evaluation criteria should include:

• Application software preference (e.g., 2D or 3D CADD, BIM, cloud provider), including licensing requirements

• Configuration and administration of servers and systems documentation defined • For 3D CADD and BIM, go/no-go on walk-through simulation for operations checks,

interference checks and construction planning and scheduling • Owner/contractor standard symbols and details • Handling of life cycle facility data including asset information, models and electronic

documents • Information technology infrastructure to support electronic modeling systems, including

uninterruptible power systems (UPS) and disaster recovery • Security and auditing requirements defined • Physical model requirements (3D printing)

M.2 Deliverables Defined The following items should be included in a list of deliverables:

• Drawings • BIM deliverables (e.g., as-built model, required elements, facility data, QA reports) • Project correspondence • Project Process Safety Management (PSM) documents • Permits • Project data books (quantity, format, contents and completion date) • Equipment folders (quantity, format, contents and completion date) • Design calculations (quantity, format, contents and completion date) • Spare parts special forms • Loop folder (quantity, format, contents and completion date) • Procuring documents • Isometrics/field erection details • As-built documents • Quality assurance documents


• Requirements to update existing (legacy) documentation/models and as-built drawings, including equipment folders/asset management systems

• Procedures for retiring an asset including the documentation requirements, spare parts inventory and accounting requirement

39

M.3 Distribution Matrix A distribution matrix for document control should be developed that addresses most correspondence and all deliverables. It denotes who is required to receive copies of documents at the various stages of the project. Some documents may be restricted due to proprietary nature.

N. PROJECT CONTROLS N.1 Project Cost Estimate An estimate of appropriate class has been prepared. It should include the following cost categories:

• Design costs • Construction/demolition costs, including equipment, labor, materials, subcontracted cost • Professional/service fees • Construction management costs • Pre-commissioning and start up activation costs • Qualification and validation costs, if required • Escalation costs • Owner costs • Required permitting, vendor assistance, spare parts and start-up materials costs • Taxes, levies, and insurance • Costs such as currency exchange, import/export fees, transoceanic shipping • Other overhead costs • Contingency costs consistent with the level of confidence required and established using

acceptable methods of risk analysis

An appropriate estimate at the end of FEL 3 (Basic Design) must be a material take off (MTO) based estimate providing a +/- 10% quality estimate (e.g., AACE Class 3 estimate, or as otherwise defined by corporate procedures) suitable for funding or bidding a project. It will be in sufficient detail to establish detailed control budgets for project execution.

All estimates must be:

• Based on technical and execution planning documents at the level of availability, completeness and maturity expected for the project phase at which the estimate is prepared

• Accompanied by a written Estimate Basis document coordinated with the schedule and Schedule Basis document

• Validated against available industry or corporate metrics for similar projects, and be rigorously reviewed for quality

Provisions to integrate contractor estimating systems with project requirements should be specified

N.2 Project Change Control A process has been established and documented that provides for the identification and management of changes to project scope, as well as changes to contractors and suppliers. The process must address assessment and approval requirements and workflows. The process should take into consideration:

40

• Change Logs to be maintained, including content required • Level of approval necessary, including identification of the individual(s) responsible for

authorizing change • Time required for reviews and approvals • Documentation required • Impact on project:

o Schedule o Quality o Cost

Provisions to integrate contractor change control systems with project requirements should be specified.

N.3 Project Cost Control Procedures for controlling project cost must be in place and responsibilities assigned. These procedures must substantially address significant cost control requirements, which may include:

• Financial (client/regulatory) • Phasing or area sub-accounting • Capital versus non-capital expenditures • Reporting requirements for budgeted, committed, actual, to-go, forecast at completion

costs, and variances • Payment schedules and procedures • Cash flow projections/draw down analysis • Detailed and integrated work breakdown structure (WBS) and/or cost breakdown

structure (CBS) that accurately captures project scope is created and implemented Costs for each project phase

• Periodic control check estimates • Change order management procedure, including scope control and interface with

information systems • Costs pertaining to right-of-way acquisition and utility adjustment during project

execution • Project and financial control software • Specifications for the required frequency of reporting

Provisions to integrate contractor cost control systems with project requirements should be specified,

41

N.4 Project Schedule Control A schedule of appropriate level of detail addressing the entirety of the project scope has been prepared. Typical items to be addressed in preparing the schedule include:

• Milestones • Identification of critical path without a negative float • Inclusion of early/late dates and total float columns in the schedule • Inclusion of actual/forecast and baseline bars in the schedule • Interfaces with third parties • Required submissions and/or approvals • Resource loading requirements • Contingency, schedule reserve, or float time

An appropriate Schedule at the end of FEL 3 (Basic Design) will provide an AACE Level 3 schedule and critical path method (CPM) analysis to define the critical path. The schedule must be in sufficient detail to permit detailed AACE Level 4 lists of deliverables and completions dates to be generated from the schedule.

The schedule is necessary for design and construction of the facility. A schedule format and control procedures should be developed during front end planning and should include assignment of responsibilities.

All schedules will address all required efforts to complete the total project scope, including for example:

• Site Surveys, geotechnical reports, field investigations • Permitting or regulatory approvals • Pre-commissioning, commissioning and start-up • Qualification and validation • Liquidated damages/incentives • Unusual schedule considerations • Required documentation/responsible party • Owner determination of how special project issues will be considered

o Selection, procurement and installation of equipment o Stages of the project that must be handled differently than other project stages o Tie-ins, service interruptions and road closures o Other special project issues o Force majeure o Unscheduled delays due to adverse weather o Specifications for the required frequency of reporting

All Schedules must be:

• Based on adequate schedule logic addressing the relationships between activities • Based on the current approved project execution plan. • Accompanied by a written schedule basis document coordinated with the estimate and

estimate basis • Validated against available industry or corporate metrics for similar projects and be

rigorously reviewed for quality

42

Provisions to integrate contractor schedule control systems with project requirements should be specified.

For more information on standards related to schedule levels, see AACE 37R-06 Schedule Levels of Detail.

N.5 Progress Measurement Procedures have been put in place to measure progress and performance for the upcoming project phase, as well as generally specifying methods to be utilized in downstream phases. Progress measurement systems may include:

• Defined systems for measuring Earned Labor Hours and Percent Complete, Physical Progress for Engineering and Construction work as may be applicable in the upcoming project phase

• Defined systems for measuring Earned Value for assessing the preparation or validation of payment requests

• Reconciliation with the approved budget estimate • Incorporation of defined and accepted standards for measuring physical progress, such

as the utilization of standard rules of credit • Acquisition of Actual Labor Hours at an appropriate cut-off date, level of detail and work

breakdown to allow productivity to be measured vs. approved budget labor hours • Ability to indicate both cumulative and reporting period progress and productivity to-date • Specifications for the required frequency of reporting • Discipline specific quantity-based commodity curves based on schedule are defined

(e.g., isometric drawings, foundations, quantity released/completed per week)

Provisions to integrate contractor progress measurement systems with project requirements must be specified.

For more information on measuring earned value, see IR 244-3 Project Controls and Management Systems Interface Management.

43

N.6 Risk Management A Risk Management Plan is in place to ensure that significant risks unique to the project have been identified, evaluated, and documented. A Risk Register has been created, and output from project assessment exercises such as PDRI have been included. Mitigation plans have been developed, with appropriate contingencies for high likelihood, high impact risk events included in the project budget and schedule. The Risk Management Plan needs additionally to address how remaining risk levels will be addressed in future project phases, including methods to be used, responsible parties, and how these assessments will integrate with remaining contingency costs to be forecasted in Cost Control reports.

Typical risk issues may include:

• Design issues (e.g., technology maturity, site location, performance of installed equipment)

• Construction delivery (e.g., availability of crafts/labor, site discovery, procurement, environmental/regulatory, site logistics, impact on/from operations)

• Management performance (e.g., project, construction) • Business conditions/requirements • Unforeseen issues related to the unique characteristics of renovations projects (e.g.,

hazardous materials, unknown underground structures or utilities) • Existing conditions of the facility • Security clearance/access control in operating areas during project execution • Safety of occupants during emergency conditions related to renovation activities

For more information on renovation and revamp risks, see IR 242-2 Front End Planning for Renovation & Revamp Projects.

P. PROJECT EXECUTION PLAN P.1 Project Organization The project team should be identified including roles, responsibilities and authority. Items to consider include:

• Core team members (e.g., design, execution, health, safety and environmental, quality) • Governance structure • Project manager assigned • Project sponsor assigned • Customer representatives assigned • Operations representatives assigned to define and support requirements • Working relationships between participants • Communication channels • Organizational chart • Project goals/key results areas (e.g., LEED, milestones, overtime, safety) • Approval responsibilities/responsibility matrix • Documented signature authority

44

P.2 Owner Approval Requirements Owner approval requirements have been developed. This document clearly defines all documents that require owner approval such as:

• Deliverables that require formal approval, for example: o Drawings o Vendor information o Commissioning / Qualification / Validation Plan o Site Logistics / Health, Safety and Environmental (HSE) Plan o Purchase documents:

• Data sheets • Inquiries • Bid tabs • Purchase orders

o Electronic models • Milestones requiring approval, for example:

o Comment o Approval o Bid issued o Construction

• Protocols, including durations of approval cycle compatible with schedule • Individual(s) responsible for reconciling comments before return • Change management approval authority

P.3 Engineering & Construction Plan This documented plan identifies the methodology to be used for engineering and construction in the project. Items should include:

• Organizational structure of the project team • Responsibility matrix • Work Breakdown Structure (WBS) • Delegated design strategy • Design assist resources • Selected project delivery strategy (e.g., design/build, construction manager at risk,

competitive sealed proposal, bridging, design- bid-build, construction manager as agent, parallel prime contractors)

• Subcontracting strategy • Building Information Model (BIM) execution plan • Construction • Design Support Plan in field during construction and completion • Quality assurance (QA)/quality control (QC) plan • Warranty period support • Work week plan/schedule • Pre-fab/module plan • Construction sequencing of events • Plans to minimize interruptions to ongoing operations • Site Logistics Plan • Safety requirements/program • Environmental program • Security requirements/program (e.g., access to site, inspection, background checks) • Identification of critical lifts and their potential impact on operating units

45

• Information and communication technology infrastructure to support field operations, including licensing requirements


• Flexible contracting arrangements for renovation projects such as a combination of unit price, cost reimbursable and lump sum

• Risks related to unforeseen conditions (e.g., inside walls, inaccurate record drawings) • Specialized contractors for renovation and revamp activities, such as hazardous

abatement or heavy haulers • Responsibility for critical maintenance activities in the existing facility (e.g., routine

maintenance during construction) • Permits and approvals when working in or near continuing operations (e.g., hot work

permits, temporary partitions, confined space, lift plans, environmental remediation, appropriate working heights)

• Coordination between multiple contractors and/or maintenance activities

P.4 Shut Down/Turn-Around Requirements Required shut downs or turn-arounds have been identified and documented. Special effort should be made to contact the Shutdown/Turnaround Manager for “customer” requirements relative to the unique issues surrounding a Shutdown/Turnaround. Typical issues to consider include:

• Definitions of the scope of work to be accomplished during such down times • Scheduled instructions for the down time • Timing of outages • Interface with other ongoing projects and operations • Work force scale up and training and staff movement logistics • Work protection considerations for the shutdown/turn-around • Accuracy of information regarding the facility is known • Standard reporting for progressing, forecasting and frequency required by the

Turnaround Manager • Identification of who approves emergent work-scopes during Turnaround and any

“hurdle” criteria it must meet to be approved. • Identification of unique risks as a result of multiple projects working concurrently • Identification of any “must do” requirements leading up to the Shutdown/Turnaround • Required emergency purchase/rental plans for materials, subcontractors, equipment,

facilities, etc. • Standard software required for integrating the master schedules (e.g., Primavera) • The “triage” process for establishing priorities when resources are not available or there

is a conflict/interference in space, equipment, etc. • Manage conflicting contractual arrangements which may inhibit timely completion • A functional accountability matrix has been established that will enable communication

across multiple projects • Safety

P.5 Commissioning/Qualification/Validation Plan The Commissioning/Qualification/Validation requirements have been defined and a responsibility matrix established. A plan has been documented and approved that addresses areas such as:

• Plan integration with the project schedule • Site impact assessment (direct/indirect/no impact)

46

• Cost assessment related to the Responsibility Matrix • Protocols • Change controls • Data and document requirements (DDR) • Risk assessment (e.g., facility/functional, good manufacturing practices, health, safety

and environmental) • System-level and component-level impact assessments • Operation and Maintenance Procedures for the following:

o System operation o Startup/shutdown o System security

• Design/Operational Qualification o System functionality and traceability o Clear definition of mechanical/electrical/hardware acceptance/approval

documentation requirements o User acceptance testing identified

o Test plan matrix integrated with utility systems

P.6 Startup & Turnover Requirements The required sequence for turnover to the asset owner and startup requirements have been defined and responsibilities established. A process is in place to ensure that startup and turnover planning will be performed. Planning should address:

• Startup & turnover goals • Project, Contractor, and Owner responsibilities and involvement (and associated costs)

in: o Commissioning/Qualification/Validation o Training o Testing

• Substantial Completion (e.g., certification of occupancy, partial facility start-up)

• Mechanical Completion, defined as physical installation conformity of the plans and specifications allowing the Owner to accept the works except for minor punch list items.

• Sequencing of startup and turnover integrated with schedule, including system identification and priority

• Turnover packages (TOP’s) • Technology startup support on-site, including information technology • Transfer of Care Custody and Control (TCCC) Procedure • Raw materials • Off-grade waste disposal • Quality assurance/quality control • Work force requirements

47

P.7 Training Requirements Training requirements have been defined and responsibility established. Owners of training-related costs have been identified. Training has been identified in areas such as:

• Control systems • Information systems and technology • Equipment operation • Maintenance of systems • Training materials and equipment (e.g., manuals, simulations) • Safety

P.8 Environmental & Safety Procedures Safety procedures, responsibilities and the authority with jurisdiction must be identified for design consideration and construction. Safety issues to be addressed may include:

• Hazardous material handling • Interaction with the public • Working at elevations/fall hazards • Evacuation plans and procedures • Drug testing • First aid stations • Spill containment • Permit to work requirements and approvals (e.g., confined space, hot work, lock out tag

out) • Waste management • Operating plant interface (e.g., maintenance of traffic/operations, joint observations &

resolution) • Accident reporting and investigation • Pre-task planning • Safety orientation and planning • Safety incentives


• Access to emergency equipment in existing facility during construction, including eye-wash stations, safety showers, etc.

• Worker and occupant safety issues/exposure and monitoring during R&R for: o Lead o Asbestos o PCB o Radiation o Chromium (stainless steel welding) o Hazardous or toxic chemical/biological contamination o Fluorescent tubes/mercury and heavy metals

• Access control, traffic control plans and existing material flows during renovation activities

• Permitting plans/coordination of responsibility for working in and around operating equipment and occupied spaces

• Scaffolding design and permitting when erecting in existing or operating areas • Lockout/tagout procedures defined and enforced • Decommissioning and decontamination procedures in place to ensure safety • Segregation of demolition activities for R&R projects from new construction

PDRI for MLS - valencyinc.comvalencyinc.com/wp-content/uploads/2017/10/PDRI-for-MLS-Element... · 0...

Documents

Transcript of PDRI for MLS - valencyinc.comvalencyinc.com/wp-content/uploads/2017/10/PDRI-for-MLS-Element... · 0...