PROCESS PLANT ENGINEERING ACTIVITY MODEL

Process Plant Engineering Activity Model

The information in this document is subject to change without notice.

Copyright Notice

The copyright of the contents of this document is assigned to the Process Industries STEP Consortium and its successors. However the
contents may be freely distributed or copied, in full or part, provided due acknowledgement is made.

Acknowledgements

The following organisations provided the information that was used to generate the model and reviewed the model at various stages of its
production.

AMEC Engineering Ltd Lloyd’s Register of Shipping

AKZO Engineering bv Nuclear Electric plc
British Nuclear Fuels plc National Institute for Standards & Technology
Eutech Engineering Solutions Ltd Process Industries STEP Consortium (PISTEP)
Harrow Associates Shell International
ICI Engineering Ltd SINTEF
Ingevision Framatome Systems d’Information The British Petroleum Company plc
John Brown Engineers & Constructors Ltd University of Newcastle upon Tyne

2
Introduction
This model and its associated documentation has been produced as an aid to those involved in the production of Application Protocols for
the Process Industries in the STEP (ISO 10303) standard. It provides an overview of the main activities and data flows associated with the
life cycle of process plant. It is emphasised that the aim of the model is not completeness but communication to those who require to
understand the main interactions between the major phases of engineering activities in the process plant life cycle. With this aim only the
major data flows are shown and minor data flows and feeds back to earlier phases of the life cycle have been ignored. The activities are
depicted as serial streams for the process and engineering activities. However, the activities may be ignored, combined or performed
concurrently dependent upon the requirements of the task to be undertaken.
The model will be made available in four forms, a paper document (this document), an electronic version of this document in Microsoft
Word for Windows1 version 3.0 or 6.0 or Wordperfect 5.12 for DOS, a Microsoft Powerpoint file suitable for version 3.0 or 4.0, a coloured
wall chart (A0) and a Microsoft VB basic program. Copies may be obtained from The Process Industries STEP Consortium at:

QMS Contact: W R Mesley

Beech House Telephone: 01252 878482 (Outside UK: +44 1252 878482)
1 Yorktown Road Facsimile: 01252 877386 (Outside UK: +44 1252 877386)
Sandhurst
Camberley
Surrey
GU17 8DX
United Kingdom

Purpose

To identify the activities which create and use engineering data that we wish to share and exchange in the Process Industries.
Something that engineers in the Process Industries will readily understand and identify with.

Viewpoint

A Plant Operators view based upon the Facility and Equipment life cycle.

1
Microsoft, Word for Windows, Powerpoint and VB basic are registered trade marks and products of the Microsoft Corporation.
2
Wordperfect is a registered trademark of the Wordperfect Corporation.
3
Context Statement
This activity model provides a simplified view of the Process Plant Life Cycle activities and indicates areas of interest and data flows that
may be modelled in a more formal manner. As such this model should prove useful in planning and developing Application Protocols to
meet the needs of the Process Industries within the ISO 10303 (STEP) environment.

Exclusions and Inclusions

The model excludes:
♦ 1. Design and manufacture of standard parts. e.g. Pumps, valves etc.
♦ 2. Development, Marketing and Transportation (other than pipelines) of manufactured product.
♦ 3. General Management activities.
♦ 4. The management of human resources and the supply of computing services.
♦ 5. Minor data flows. e.g. Minor Feedback's etc.

The model includes:

♦ 1. Engineering management activities.
♦ 2. Authorisations and Permissions both internal and external. e.g. License to Operate

4
BLANK PAGE

5
 PROCESS PLANT ENGINEERING ACTIVITY MODEL Safety & Environment Case
MANAGEMENT ACTIVITIES

SET ENGINEERING PRODUCE & MAINTAIN CONTROL OPERATIONS OBTAIN REGULATORY BODIES
POLICY & FEASIBILITY & & ENGINEERING AGREEMENT WITH
STANDARDS FINANCIAL CASE ACTIVITIES REGULATORY BODIES
Regulatory Requirements
Authorizations
Process Definition Performance Requirements
Control Philosophy Operating Procedures As Built Drawings Plant Status
Costs, Benefits & Timings Operating Conditions Operating Procedures Ground Drains Status
Safety / Regulatory Requirements Alarm / Trip Settings Acceptance Test results Safety Case
Safety and Environment Case Handover Certificate As Built & As Modified Drawings

PRODUCE
CONCEPTUAL PRODUCE DETAILED COMMISSION PROCESS OPERATE DECOMMISSION
PROCESS DESIGN PROCESS DESIGN & HANDOVER PLANT PLANT PLANT

Detailed Process Design Plant Status

Process Stream Data Availability Requirements Engineering Work Requests Plant Records
Process Flow Diagrams Safety Systems Specifications Working Conditions Requirements Inspection Requirements
As Built Drawings Engineering Work Permits Regulatory Approvals
Costs, Benefits & Timings Operating Procedures Equipment Commissioning Procedures Acceptance of Engineering Work
Codes & Standards Equipment Operating Procedures
Inspection & Testing Records Inspection Requirements
Handover Certification As Built Drawings Work Permit Requests
Preliminary Engineering Design As Built Equipment Specifications Notification of Work
Engineering Philosophies Spares Lists Completion
Detailed Engineering Design Installation Procedures
Availability Requirements
Equipment Procedures Maintenance Procedures
Cost & Time Estimates State of Equipment
Vendor Drawings Inspection Results
Safety / Regulatory Requirements Value of Equipment
Spares Lists Unfinished Work Details
Codes & Standards Equipment Records

PRODUCE CONCEPTUAL PRODUCE DETAILED CONSTRUCT & MAINTAIN

ENGINEERING PRE-COMMISSION DEMOLISH PLANT &
ENGINEERING EQUIPMENT
DESIGN PLANT RESTORE SITE
DESIGN

Materials & Equipment Materials & Equipment

Requirements & Specifications Delivery Dates Requirements & Specifications
Delivery Dates
Required on Site Dates Vendor Drawings Required on Site Dates
Vendor Drawings
Equipment Procedures Certification Certification
Delivery Dates Equipment Procedures Equipment Procedures
Vendor Drawings Equipment & Materials Equipment & Materials Catalogues
Catalogues Inspection Results Disposal Records
Materials & Equipment Certification Restoration Records
Equipment & Materials Catalogues Shipping Details
Requirements & Handover Records
Specifications Invoices Final Regulatory Approvals
Required on Site Dates
Inspection Results SUPPLIERS
Shipping Details & PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES
Payment Details FABRICATORS

P Harrow colact1 ©PISTEP 10/06/94

6
 OVERVIEW
This diagram gives an overview of the whole life cycle and shows the relationships and data flows for the level 1 activities.
1. Set Engineering Policy and Standards
Defines the engineering policy that shall be used and obtain any
codes and standards that may be required.
2. Produce and Maintain Feasibility and Financial Case
Produce and maintain the feasibility and financial case.
3. Control Operations and Engineering Activities
Prepare plans, aquire resources to execute them, check
conformance to plan and take corrective action.
4. Obtain agreement with Regulatory Bodies
Obtain agreement with regulatory bodies for the siting, design,
construction, commissioning and operation of the plant. The
engineering management activities required to obtain approval
from the regulatory bodies for the mothballing of the plant or its
demolition and subsequent site restoration.
5. Regulatory Bodies
The external regulatory bodies whose requirements must be met
at all stages of the plant life cycle. These bodies may be a
purchaser of the plant, governmental body or supra-national
organisation at various stages of the plant life cycle.
6. Produce Conceptual Process Design
Produce the preliminary Process design which will be passed to
Conceptual Engineering Design and Detailed Process Design. It will
also prepare a feasibility and financial case for management.
7
7. Produce Conceptual Engineering Design
Produce the preliminary engineering philosophies to be used
and the preliminary engineering design required for further
detailed engineering design.
This activity is often performed concurrently with the
Conceptual Process design.
8. Produce Detailed Process Design
Produce the detailed process design which provides the
specifications, requirements, codes and standards, design and
operation philosophies required for the Detailed Engineering
Design and Commissioning.
9. Produce Detailed Engineering Design
Produce the Detailed Mechanical, Electrical,
Control/Instrumentation, Plant/Building Services and
Civil/Structural Engineering Design for the plant including all
specifications, drawings, construction and commissioning plans,
3D models, materials takeoff and spares lists.
10. Procure and Control Equipment Materials and Services
Make enquiries, place purchase orders, inspect and expedite
progress, ship goods and control stock of equipment and
materials.
 16. Demolish Plant and Restore Site
11. Construct and Pre-Commission Plant The activity of demolishing the plant and restoring the site.
Construct the plant as defined by the detail design specifications Demolish Plant and Restore Site makes use of Plant Status from
to plan to meet the needs of the commissioning team. Decommission Plant, and Equipment Status from Maintain
Construction includes verification that the design has been Equipment.
satisfied and that the resulting plant is acceptable to the
commissioning team. 17. Suppliers and Fabricators
External suppliers and fabricators offering goods and services.
12. Commission Process and Handover Plant
Prove the operation of all plant systems as defined by the
detailed design specifications such that the plant can be
accepted for operation to manufacture product.
Commissioning typically consists of a number of stages
progressing from activities using either no or inert process
materials to the use of production process materials.

13. Operate Plant

Operate the plant safely, efficiently, and according to plan.

14. Maintain Equipment

Maintain the plant and equipment in a safe manner to ensure plant
operability.

15. Decommission Plant

Taking a plant out of operating service, isolating all feedstock
and services, removing all process materials from the plant, and
establishing maintenance conditions such that the plant could be
returned to operating service.

8
BLANK PAGE

9
 PRODUCE CONCEPTUAL PROCESS DESIGN
PRODUCE
DETAILED PROCESS
Define Identify DESIGN
Design Provide Input to Identify
Overall Candidate Feasibility / Safety / Regulatory
Processes Process
Requirement Financial Case Requirements

Define End
Define Unit
Requirements
Operations
Process Definition
Produce Energy / - Process Stream Properties
Identify Start Conditions & Composition
Mass Balance - Required Unit Operations
- Define Battery Limits
- Process Flow Diagrams
- Identify state of Plant Produce Composition - Energy Balance
to be modified of Process Streams Control Philosophy
Costs, Benefits & Timings
Safety / Regulatory Requirements
Define Control
Philosophy

Produce Process
Flow Diagrams

Process Stream Data

Process Flow Diagrams
Costs, Benefits & Timings

PRODUCE CONCEPTUAL ENGINEERING DESIGN P Harrow colact1 ©PISTEP 26/04/94

10
 CONCEPTUAL PROCESS DESIGN
Produce the preliminary Process design which will be passed to Conceptual Engineering Design and Detailed Process Design. It will also prepare a
feasibility and financial case for management.

1. Define Overall Requirement Produce a Process Flow Diagram identifying all major items of
equipment and Process Streams.
1.1 Define End Requirements
Define the requirements the process must satisfy. 4. Produce Feasibility/Financial Case
1.2 Identify Start conditions. For each candidate process produce estimates of capital and operating
costs, operating manpower requirements, technical/financial risk
Identify the start conditions for the conceptual process
assessments and return on investment predictions.
design, including:
• The definition of the Battery Limits. 5. Identify Safety / Regulatory Requirements
• Identification of the status of any existing plant and the Identify all features of the process and plant which are potentially
performance characteristics of its processes. hazardous and produce design philosophies to minimise/eliminate the
hazards.
2. Identify candidate processes Typical features considered:
Identify potential processes for meeting the overall requirements. • Hazardous material handling
• Effluent Treatment
3. Design Process • Fire Protection
• Pressure Relief/Containment
3.1 Define Unit Operations • Emergency Shutdown
Identify the constituent unit operations for a process. • Safety Interlocking
3.2 Produce Energy / Mass Balance Identify all features of the process and plant which are subject to
Produce mass and energy balances for the overall process and for regulatory requirements and produce design philosophies to
each unit operation. meet those requirements.
3.3 Produce Composition of Process Streams
Identify the material composition of each process stream.
3.4 Define Control Philosophy
Define the control philosophy for the process. For batch processes
include process timings.

3.5 Produce Process Flow Diagrams

11
 PRODUCE CONCEPTUAL PROCESS DESIGN

PRODUCE
DETAILED
ENGINEERING
DESIGN

PRODUCE CONCEPTUAL ENGINEERING DESIGN

Produce Conceptual Produce Conceptual Produce Conceptual Produce Conceptual Define Produce Conceptual
Determine
Mechanical Electrical Control & Safety Preliminary Civil / Structural
Engineering
Engineering Engineering Instrumentation Engineering Plant Engineering
Approach
Design Design Engineering Design Design Layouts Design

Identify Identify Identify

Review Materials of Define Review Site Produce Site Survey / Soil
Materials of Materials of
Process Construction Safety Alternatives & Investigation
Construction Construction
Design Philosophies Conditions
Produce Major Produce Major Produce Major Define Civil / Structural
Determine Equipment Design Identify Produce Philosophies
Equipment Design Equipment Design Preliminary Engineering Design
Status of Philosophy Regulatory Preliminary
Philosophy Philosophy - Equipment Lists
Existing Requirements Layout Identify Materials of - Preliminary Equipment
Plant Produce Drawings Construction
Produce Produce Specifications
Preliminary Preliminary Preliminary Define - Materials of Construction
Define Equipment & Line Equipment Containment Produce Produce Preliminary Building
Equipment - Utility Requirements
Engineering Specifications Philosophy Studies for or Module Layout Drawings
Specifications Specifications - Preliminary Layout Drawings
Design Cranage &
- Weight & Volume Estimates
Strategy Produce Cost Produce Handling Produce Preliminary
Produce Cost Produce Control - Control Systems Architecture
& Time Estimates & Time Estimates System Architecture Technical Weight & Volume - Technical Risks Assessment
Obtain Codes & Risks Assessment Estimates Engineering Philosophies
Standards Produce Produce Produce Cost - Design Philosophy
Preliminary Preliminary & Time Estimates Define Construction - Construction Philosophy
Weight & Weight & Volume Philosophy - Commissioning Philosophy
Volume Estimates Estimates Produce Preliminary - Operations Philosophy
Weight & Volume Estimates Define Building / Structural - Safety Philosophies
Define Define Commissioning Philosophy - Containment Philosophy
Commissioning Commissioning Define Commissioning Availability Requirements
Philosophy Philosophy Philosophy Cost & Time Estimates
Safety / Regulatory Requirements
Codes & Standards

P Harrow colact1 ©PISTEP 07/06/94

12
 PRODUCE CONCEPTUAL ENGINEERING DESIGN
Produce the preliminary engineering philosophies to be used and the preliminary engineering design required for further detailed engineering design.
1. Determine Engineering Approach
Determine the approach to be used in engineering of the process
definition. The following sub-activities are performed.
1.1 Review Process Design
Conduct a review of the process definition.
1.2 Determine Status of Existing Plant
Determine the status of any existing plant which is to be
modified..
1.3 Define Engineering Design Strategy
Define the strategy that will be used in the engineering
design of the plant.
1.4 Obtain Codes and Standards
Obtain the codes and standards either internal or external,
that will be used in the engineering design of the plant
2. Produce Conceptual Mechanical Engineering Design
Produce the preliminary mechanical engineering design.
2.1 Identify Materials of Construction
From the process definition, identify appropriate materials
for major process piping and equipment.
2.2 Produce Major Equipment Design Philosophy
From the process definition and the project plans, prepare an
outline statement of the rules and sequences for the design of
the major equipment.
13
2.3 Produce Preliminary Equipment, Line Lists
From the process definition, list the major process piping and
major equipment items for all disciplines.
2.4 Produce Preliminary Equipment Specifications
From the early process definition, generate preliminary
specifications for the major process piping and major
equipment items.
2.5 Produce Cost and Time Estimates
Produce project plans and budgets for capital and Design and
Engineering costs.
2.6 Produce Preliminary Weight and Volume Estimates
Add weight and volume estimates to the plant list for use in
conceptual plant layout and civil/structural design.
2.7 Define Commissioning Philosophy
Prepare an outline statement of the rules and sequences for
commissioning.
3. Produce Conceptual Electrical Engineering Design
Produce the preliminary electrical engineering design.
3.1 Identify Materials of Construction
From the process definition, identify appropriate materials
for major electrical cabling and equipment.
3.2 Produce Major Equipment Design Philosophy
Prepare an outline statement of the rules and sequences for
the design of the major electrical equipment.
 3.3 Produce Preliminary Equipment Specifications
Generate preliminary specifications for the major electrical
equipment items.
3.4 Produce Cost and Time Estimates
Produce project plans and budgets for capital and Design and
Engineering costs.
3.5 Produce Preliminary Weight and Volume Estimates
Add weight and volume estimates to the plant list for use in
conceptual plant layout and civil/structural design.
3.6 Define Commissioning Philosophy
Prepare an outline statement of the rules and sequences for
commissioning.
4. Produce Conceptual Control & Instrumentation Engineering
Design
Produce the preliminary Conceptual Control and
Instrumentation engineering design.
4.1 Identify Materials of Construction
From the process definition, identify appropriate materials
for major process instrumentation and control equipment.
4.2 Produce Major Equipment Design Philosophy
Prepare an outline statement of the rules and sequences for
the design of the major equipment.
4.3 Produce Preliminary Equipment Specifications
From the process definition, generate preliminary
specifications for the major process instrumentation and
control equipment items.
4.4 Produce Control System Architecture
Produce the control system architecture to be used on the
plant.
4.5 Produce Cost and Time Estimates
14
Produce project plans and budgets for capital and Design and
Engineering costs.
4.6 Produce Preliminary Weight and Volume Estimates
Add weight and volume estimates to the plant list for use in
conceptual plant layout and civil/structural design.
4.7 Define Commissioning Philosophy
Prepare an outline statement of the rules and sequences for
commissioning.
5. Produce Conceptual Safety Engineering Design
Produce a conceptual safety design that will meet regulatory
requirements and conform to the codes and standards in force.
5.1 Define Safety Philosophies
From the regulatory requirements and the early process
definitions, outline the safety criteria appropriate to the type
of plant concerned.
5.2 Identify Regulatory Requirements
Identify the regulatory requirements that govern the siting,
construction and operation of the type of plant concerned.
5.3 Define Containment Philosophy
From the regulatory requirements and the early process
definitions, define the underlying rules for the plant
containment design.
5.4 Produce Technical Risks Assessment
From the developing conceptual design, perform and publish
initial hazard and operability studies.
6. Define Preliminary Plant Layouts
 Study the alternative sites and produce a preliminary site layout From the siting proposals, preliminary plant layouts and
for the selected site. regulatory requirements, prepare preliminary civil and
6.1 Review Site Alternatives & Conditions structural layouts for the plant buildings or modules and the
Review the alternative sites and the conditions applicable to site.
those sites. 7.5 Produce Preliminary Weight and Volume Estimates
6.2 Produce Preliminary Layout Drawings From the preliminary civil and structural layouts, prepare
From the early process definitions, plant list and volume estimates of weight and volumes for use in cost estimates and
estimates, prepare initial plant layout proposals. foundation design.
6.3 Produce Studies for Cranage and Handling 7.6 Define Construction Philosophy
From the preliminary layout drawings and early process From the regulatory requirements and the preliminary
definitions, prepare proposals for the cranage facilities and civil/structural layouts outline the rules and sequences on
other bulk-handling operations required in plant construction which the civil/structural construction is to be based.
and operation. 7.7 Define Building/Structural Commissioning Philosophy
From the developing civil/structural design and the project
7. Produce Conceptual Civil/Structural Engineering Design plans, prepare an outline statement of the rules and sequences
Produce the civil engineering work and structural engineering for commissioning the civil/structural aspects of the plant.
required for the plant.
7.1 Produce Site Survey / Soil Investigation
Produce a site survey and investigate the soil for load bearing
and other properties.
7.2 Define Civil / Structural Philosophies
From the siting proposals, preliminary plant layouts and
regulatory requirements, prepare a statement of the design
rules and philosophies on which the civil/structural design is
based.
7.3 Identify Materials of Construction
From the siting proposals, preliminary plant layouts and
regulatory requirements, identify appropriate materials for
major aspects of the civil/ structural design.

7.4 Produce Preliminary Building or Module Layout

Drawings
15
PRODUCE CONCEPTUAL
PROCESS DESIGN

COMMISSION
PRODUCE DETAILED PROCESS DESIGN PROCESS &
COMMISSION
PLANT
Produce Produce Produce Produce
Piping & Functional Satisfy
Control Plant
Instrumentation Specification Safety
Requirements Operating
Diagrams for Equipment Requirements
Specification Procedures

Identify
Control Define Relief &
Requirements Blowdown Philosophy

Identify Define Protective

System (Including Fire) Performance Requirements
Trip Operating Procedures
Requirements Philosophy
Operating Conditions
Alarm / Trip Settings
Produce Define Hazardous Areas Safety and Environment
Case
Control
Requirements Produce Safety &
Specification Environment Case

Detailed Process Design

- Piping & Instrumentation Diagrams
- Functional Specifications
- Control Specifications
- Alarm / Trip Settings
- Utility Systems Requirements
PRODUCE - Design Philosophies
Availability Requirements
DETAILED Safety Systems Specifications
ENGINEERING Operating Procedures
DESIGN Codes & Standards
P Harrow colact1 ©PISTEP 26/04/94

16
 PRODUCE DETAILED PROCESS DESIGN

Produce the detailed process design which provides the specifications, requirements, codes and standards, design and operation philosophies required
for the Detailed Engineering Design and Commissioning.

1. Produce Piping & Instrumentation Diagrams
Produce schematic drawings detailing equipment, instrument
and piping connectivity.
2. Produce Functional Specification for Equipment
Produce a specification for the functional requirements for all
equipment including process design conditions, material
specifications, insulation requirements and tracing requirements.
3. Produce Control Requirements Specifications
Produce the requirements specification for the plant control
systems.
3.1 Identify Control Requirements
Identify the specific control requirements for the complete
plant and for each unit operation.
3.2 Identify Trip Requirements
Identify the alarm, interlock and shutdown requirements for
the complete plant and for each unit operation.
3.3 Produce Control Requirements Specification
Produce a specification detailing the control requirements for
the plant, the alarm interlock and shutdown requirements.
Define the relief and blowdown philosophy to be used in the
plant design that will ensure safe and reliable operation of the
plant.
4.2 Define Protective System (including Fire) Philosophy
Define the protective systems philosophy for the plant
including normal and specialised fire fighting requirements.
4.3 Define Hazardous Areas
Define the hazardous areas of the plant which may arise due
to the use of toxic substances, radiation, inflammable fluids
or gases.
4.4 Produce Safety & Environment Case
Produce safety and environmental studies that may be
required by regulatory bodies or planning (Zoning)
authorities.
5. Produce Plant Operating Procedures
Produce any procedures that may be required for
Commissioning or Operation of the plant.

4. Satisfy Safety Requirements

Produce philosophies to meet the safety requirements of the
owners of the plant and regulatory authorities.
4.1 Define Relief & Blowdown Philosophy
17
 PRODUCE DETAILED
PROCESS DESIGN

PRODUCE DETAILED ENGINEERING DESIGN

Produce Detailed Produce Detailed Produce Detailed Produce Detailed Produce Detailed Produce Detailed
Mechanical Produce Building
Electrical Control & Layout & Civil / Structural Safety
& Plant
PRODUCE Engineering Engineering Instrumentation Construction Engineering Engineering
Design Services Design
CONCEPTUAL Design Engineering Design Design Design Assessment
CONSTRUCT &
ENGINEERING PRE-COMMISSION
DESIGN Produce Piping & Review & Detail Review & Detail Produce Site Produce Produce Site Survey /
Plant / Building Instrumentation Domestic Soil Investigation PLANT
Mechanical Layout
Equipment Design Electrical Plant / Building Water,
Requirements Requirements Produce 3D Sewage & Produce Room / Module
Produce Equipment Plant Model Storm Water Specifications
Handling Systems Produce Earthing Produce Clean Design
Design Requirements Earthing Coordinate Produce Civil
(Static, Requirements Interfaces Produce Construction
Produce Detailed Lightning, Power) Between Design Environmental Drawings
Mechanical Produce Areas Control
Equipment Produce Measurement Systems Design Containment
Specifications Communication Instrumentation Produce Site Design Systems
System Design Specification Construction &
Define Mechanical Installation Produce Design Process
Equipment Spares Produce Electrical Produce Actuator Methodology Lighting & Effluent Drainage
Requirements Equipment Specifications Small Power Systems
Specifications Define Test & Design
Produce Mechanical Produce Control Pre-Commissioning Design Foundation
Maintenance Produce Electrical Systems Requirements Produce Fire Structures
Procedures Cable Runs Design Specifications Protection
Systems Produce Painting & Detailed Engineering Design
Produce Power Define Signal Design Surface Finish - Detailed Equipment Specification
Distribution Transmission Specifications - Piping & Instrumentation Diagrams
Systems Pathways - 2D Schematics
Design Produce Weight - 3D Model
Produce Environmental Schedules - Construction Drawings
Produce Electrical Control Requirements Equipment Procedures
Environment for Instrumentation Produce Bill Of - Installation Procedures
Control Quantities - Commissioning Procedures
Requirements Define Instrumentation - Operating Procedures
& Control Equipment - Maintenance Procedures
Define Electrical Spares Requirements Vendor Drawings
Equipment Spares Spares Lists
Requirements Produce Instrumentation
& Control Maintenance
Produce Electrical Procedures
Maintenance
Procedures

Equipment & Materials Requirements

and Specifications
Required on Site Dates
PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES P Harrow colact1 ©PISTEP 26/04/94

18
 PRODUCE DETAILED ENGINEERING DESIGN
Produce the Detailed Engineering Design for the plant including all specifications, drawings, construction and commissioning plans, 3D models,
materials takeoff and spares lists.
1. Produce Detailed Mechanical Engineering Design
Produce the detailed engineering design for the mechanical
equipment and piping for the plant.
1.1 Produce Mechanical & Piping Equipment Design
From the equipment data sheets, piping and instrumentation
diagrams and plant layouts, produce detailed procurement
specifications for mechanical equipment items and
fabrication specifications for piping.
1.2 Produce Equipment Handling System Design
From the process facility data and mechanical handling
equipment specifications, produce designs for plant
mechanical handling systems.
1.3 Produce Detailed Mechanical Equipment Specifications
Produce specifications for all items of mechanical equipment
on the plant.
1.4 Define Mechanical Equipment Spares Requirement
Define the spares requirement for all items of mechanical
equipment on the plant.
1.5 Produce Maintenance Procedures
Produce the procedures to effectively maintain all items of
mechanical equipment on the plant.
2. Produce Detailed Electrical Engineering Design
Produce the detailed engineering design for the electrical
equipment and cabling for the plant.
19
2.1 Review & Detail Plant / Building Electrical Requirements
Review the electrical requirements received from Detailed
Process Design and Conceptual Engineering Design and
refine to give a detailed list of requirements.
2.2 Produce Earthing requirements (Static, Lightning,
Power)
Produce the requirements for protection of the plant from the
build-up of static electricity, lightning protection and
earthing of electrical power systems equipment.
2.3 Produce Communication System Design
Produce the design of any communication systems required
for the operation of the plant.
2.4 Produce Electrical Equipment Specifications
Produce specifications for all items of electrical equipment
on the plant.
2.5 Produce Electrical Cable Runs Design
Produce the electrical cable runs design for the plant.
2.6 Produce Power Distribution Systems Design
Produce the power distribution systems design.
2.7 Produce Electrical Environment Control Requirements
Produce the requirements for environmental control of
electrical equipment on the plant.
2.8 Define Electrical Equipment Spares Requirement
Define the spares requirement for all items of electrical
equipment on the plant.

2.9 Produce Maintenance Procedures
Produce the procedures to effectively maintain all items of
electrical equipment on the plant.
3. Produce Detailed Control & Instrumentation Engineering
Design
Produce the detailed engineering design for the control and
instrumentation equipment and cabling for the plant.
3.1 Review & Detail Instrumentation Plant / Building
Requirements
Review the instrumentation requirements received from
Detailed Process Design and Conceptual Engineering Design
and refine to give a detailed list of requirements.
3.2 Produce Clean Earthing requirements
Produce the requirements for clean earths for the
instrumentation system.
3.3 Produce Measurement Instrumentation Specification
Produce the specification for instrumentation used to
measure process conditions in the operation of the plant.
3.4 Produce Actuator Specifications
Produce specifications for all actuators on the plant.
3.5 Produce Control Systems Specification
Produce the control systems specification for the plant.
3.6 Define Signal Transmission Pathways
Define the signal transmission pathways required by the
instrumentation system.
3.7 Produce Environmental Control Requirements for
Instrumentation
Produce the requirements for environmental control of
instrumentation equipment on the plant.
20
3.8 Define Instrumentation Equipment Spares Requirement
Define the spares requirement for all items of instrumentation
equipment on the plant.
3.9 Produce Maintenance Procedures
Produce the procedures to effectively maintain all items of
instrumentation equipment on the plant.
4. Produce Layout & Construction Design
From the Equipment design produce the layout and construction
design
4.1 Produce Site Layout Drawing
From the preliminary civil/structural layouts and the detailed
plant layouts, prepare the final site layout drawing.
4.2 Produce 3D Model
From the piping and instrumentation diagrams and
preliminary plant layouts, produce the 3D plant model
incorporating plant structure, piping, ventilation, cabling
reservations and plant.
4.3 Co-ordinate Interfaces Between Design Areas
Co-ordinate the interfaces between design areas from
different design sources, to ensure compatibility of all
aspects of design across the boundaries.
4.4 Produce Site Construction & Installation Methodology
From the 3D layouts, the floor plans/elevations and the
developing detailed plant design, produce all layout and
construction detail drawings that are necessary to support
plant construction activities.
4.5 Define Test & Pre-Commissioning Requirements
Define the test and pre-commissioning requirements for the
plant.
5. Produce Plant/Building Services Design
From the piping and instrumentation diagrams and preliminary
plant layouts, produce detailed piping, ventilation and plant
layouts.
5.1 Produce Domestic Sewerage and Storm Water Design
From the detailed plant layouts and the site layout, produce
the detail drawings to define the domestic sewerage and
storm water management systems.
5.2 Produce Environmental Control Systems Design
From the room data sheets, equipment data sheets and the
detailed plant layouts, produce detailed procurement
specifications for air-conditioning and other environmental
control systems.
5.3 Produce Lighting and Small Power Design
From the room data sheets and the detailed plant layouts,
produce the layouts and procurement specifications to
support the design and installation of the lighting and small
power systems.
5.4 Produce Fire Protection Systems Design
From the detailed plant layouts and the regulatory
requirements, produce the layouts and procurement
specifications to support the design and installation of the fire
protection systems.
6. Produce Detailed Civil/Structural Engineering Design
From the detailed plant layouts produce the detailed civil and
structural designs required for the plant.
6.1 Produce Site Survey / Soil Investigation
21
From the preliminary plant siting studies, perform physical
surveys of ground contour, groundwater flow and underlying
geology to support the choice of site.
6.2 Produce Room/Module Specifications
From the process facility data, detailed plant layouts and
equipment data sheets, produce the room or module
specifications.
6.3 Produce Civil Construction Drawings
Produce the drawings for any civil construction work
required.
6.4 Design Containment Systems
Implement the containment systems design in civil and
structural design features where appropriate.
6.5 Design Process Effluent Drainage Systems
From the detailed process flow diagrams and the detailed
plant layouts, design the necessary collection and storage
facilities and pipework to allow the removal of process
effluents.
6.6 Design Foundation Structures
From the preliminary civil/structural weight estimates, the
site survey data and seismic design criteria, produce the
detailed plant foundations designs.
6.7 Produce Painting and Surface Finish Specification
Produce the painting and surface finish specification for the
plant and ancillary buildings.
6.8 Produce Weight Schedules
Produce weight schedules for civil / structural items where
appropriate.
6.9 Produce Bill of Quantities
 From the detailed civil/structural layouts, derive the Bills of
Quantities needed to enable plant construction.

7. Produce Detailed Safety Engineering Assessment

Produce a detailed safety engineering assessment for the plant.

22
BLANK PAGE

23
 Equipment & Materials Catalogues
- Equipment & Materials Specifications
- Equipment & Material Availability & Prices
Equipment & Materials Catalogues
- Equipment & Materials Specifications - Spares Lists
- Equipment & Material Availability & Prices Delivery Dates
- Spares Lists Vendor Drawings
Delivery Dates Certification
Vendor Drawings
Certification Equipment Procedures
Equipment Procedures - Installation Procedures
- Installation Procedures - Commissioning Procedures
- Commissioning Procedures - Operating Procedures
- Operating Procedures
- Maintenance Procedures - Maintenance Procedures
Inspection Results
Shipping Details

PRODUCE
DETAILED CONSTRUCT & MAINTAIN
Equipment & Materials Catalogues
- Equipment & Materials Specifications
ENGINEERING PRE-COMMISSION EQUIPMENT
- Equipment Availability & Prices DESIGN PLANT
- Spares Lists
Delivery Dates
Vendor Drawings PROCURE & CONTROL EQUIPMENT MATERIALS & SERVICES
Certification
Equipment Procedures
- Installation Procedures Maintain Ship Goods Control
Issue Evaluate Commit Expedite Release for
- Commissioning Procedures Suppliers From & Issue
Enquiries Bids Purchase Manufacture Inspect Shipment
- Operating Procedures List Supplier Equipment
From Supplier
- Maintenance Procedures & Materials
Invoices

Maintain List Compile Condition Produce Inspect Issue Pack Produce Material
Of Preferred Bidders Expedite
Bids Purchase Equipment, Release Note Goods Stock Strategy
Suppliers List Progress
Orders Materials
SUPPLIERS & Select Authorize & Services Close out Make Unload
Maintain Produce Supplier Confirm Purchase Shipping Goods
FABRICATORS Relationship Enquiry Stage
Final Respond to Order Arrangements
with Suppliers Documents Payments
Conditions Concession Store Goods
of Contract Requests Authorize Ship Goods
Compile Respond to
Technical Final Control &
Conditions Payments Monitor
of Contract Queries
Equipment & Materials Requirements & Stock
Specifications
Required on Site Dates Issue & Transport
Inspection Results Goods To Required
Shipping Details Location
Payment Details

P Harrow colact1 ©PISTEP 10/06/94

24
 PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES
Make enquiries, place purchase orders, inspect and expedite progress, ship goods and control stock of equipment, and materials.
1. Maintain Suppliers List
Keep up to date records of potential suppliers of equipment,
materials or services, including information on pre-
qualifications, range of goods and services available etc.
1.1 Maintain List of Preferred Suppliers
Issue and record pre-qualification questionnaires for possible
suppliers of equipment, materials and services, including
information on range of goods and services offered.
1.2 Maintain Relationship With Supplier
Maintain the relationship and keep up to date with product
and technological advances etc.
2. Issue Enquiries
Issue the full set of enquiry documents to suppliers listed on the
bidders list.
2.1 Compile Bidders List
From the maintained suppliers lists, list those vendors who
have suitable experience and pre qualifications to tender for
the required goods and services.
2.2 Produce Enquiry Documents
Compile all the enquiry documentation, from the equipment,
materials and service requirements.
2.3 Compile Conditions Of Contract
Determine the contractual conditions that will apply to the
eventual purchase order. These are part of the issued enquiry.
25
3. Evaluate Bids
Review all the tender documents received from suppliers and
make the recommendations as to where to place the purchase
order.
3.1 Condition Bids
Resolve the non conformance’s within the tender documents
from suppliers
3.2 Select Supplier
Choose the successful supplier from the tenders received
4. Commit Purchase
Issue purchase order to the successful supplier.
4.1 Produce Purchase Orders
Compile all the purchase documentation, from the
equipment, materials and service requirements.
4.2 Compile Final Conditions Of Contract
Determine the contractual conditions of contract that will
apply to the purchase order from the condition bid stage.
These are part of the purchase order.
5. Expedite Manufacture
Review suppliers performance and contract progression against
promised delivery and required on site dates.
5.1 Expedite Progress
Review supplier progress, produce and issue a progress
report to aid the detailed design and construction activities
 5.2 Authorise Stage Payments Check that final payments are due. Authorise and make
Check that stage payments are due. Authorise and make payments upon the conditions of contract being met that
stage payments upon the conditions of contract being met allow payments to be made
that allow stage payments to be made.
5.3 Respond To Technical Queries 8. Ship Goods from Supplier
Resolve any technical queries that occur during the Arrange and transport the goods from the suppliers to the site or
manufacturing period. facility.
8.1 Pack Goods
6. Inspect Pack the equipment or materials suitably, and make ready for
Inspect the equipment, materials and services for compliance to transportation from the suppliers.
specification 8.2 Make Shipping Arrangements
6.1 Inspect Equipment, Materials & Services Arrange transportation for equipment and materials
Inspect the equipment, materials or services being provided 8.3 Ship Goods
noting problem areas that either need reworking or Ship goods to site or holding area.
concessions granting.
6.2 Respond To Concession Requests 9. Control & Issue Equipment & Materials
Organise and respond to any request for concessions, liaising Control and issue equipment and materials to construction or
with the detailed engineering design. maintenance.
9.1 Produce Material Stock Strategy
7. Release for Shipment from Supplier Produce a strategy for holding stock required for construction
Authorise the shipment of equipment or materials at the end of and maintenance.
the fabrication and manufacture contract 9.2 Unload Goods
7.1 Issue Release Note Unload the goods from their transportation for storage.
After the last inspection, of the finished items or work, issue 9.3 Store Goods
a release note that states that the items or work are to Provide storage of equipment and materials
specification and are satisfactory. 9.4 Control & Monitor Stock
7.2 Close Out Purchase Order Monitor stock levels to ensure equipment and materials are
Check and confirm that all contractual requirements have available when required and raise requests to purchase more
been met by the supplier. stock if necessary.

9.5 Issue Goods and Transport Goods to Required Location

7.3 Authorise Final Payments
26
When details of equipment and materials requirements are
received from maintain plant check if equipment or materials
are in stock. If so issue the equipment or materials to
maintain plant.

27
 COMMISSION PROCESS
& HANDOVER PLANT
As Built Drawings
Equipment Commissioning Procedures
Equipment Operating Procedures
Inspection & Testing Records
Handover Certification
PRODUCE
DETAILED MAINTAIN
ENGINEERING CONSTRUCT & PRE-COMMISSION PLANT EQUIPMENT
DESIGN

Produce Establish Produce Handover

Construction Construction Erect To Process
As-Built Pre-Commission
Plans Services Plant Commissioning
Surveys

Produce Perform Perform Clean Plant for

Contract Civil / Conformance Testing and
Plan Structural Checks Commissioning
Construction
Produce
Produce Prepare Equipment
Construction Erect Major As Built Drawings
As-Built for Commissioning
Plan Plant Items As Built Equipment Specifications
Specifications
& Drawings Perform Spares Lists
Construct Pre-commissioning Installation Procedures
Piping Identify Tests Maintenance Procedures
Unfinished Inspection Results
Install Electrical Work Perform Baseline Unfinished Work Details
& Instrumentation Inspection
Systems

Complete Special
Finishes, Thermal
Insulation & Painting

PROCURE & CONTROL

EQUIPMENT, MATERIALS
& SERVICES

P Harrow colact1 ©PISTEP 26/04/94

28
 CONSTRUCT and PRE-COMMISSION PLANT
Construct the plant as defined by the detail design specifications and plan to meet the needs of the commissioning team. Construction includes
verification that the design has been satisfied and that the resulting plant is acceptable to the commissioning team.
1. Produce Construction Plans
Produce plans used in the construction of the plant.
1.1 Produce Contract Plan
The activity of producing a contract plan which details the
organisations responsible for implementing the work
packages of the construction plan.
1.2 Produce Construction Plan
Produce a construction plan which identifies all construction
work packages, their time and resource requirements and
dependencies.
2. Establish Construction Services
The temporary construction services required for the
construction of the plant.( e.g. temporary office, workshop,
carpark etc. ).
3. Erect Plant
Construct the plant as defined by the detailed design
specifications and verification that the construction work
satisfies the design.
3.1 Civil / Structural Construction
Perform the civil and structural work as defined by the civil
and structural detail design specifications, and verification
that the design has been satisfied.
(e.g. establishment of foundations, drainage systems, effluent
containment systems, buildings, pipe bridges etc).
29
3.2 Erect Major Plant Items
Locate major plant items on foundations or structures as
defined by the detail design specifications, and verify that the
design has been satisfied.
Major plant items are considered to be fabricated elsewhere
and supplied to construction essentially complete. In some
cases assembly of sub units may be required during
construction e.g. a large column may be transported to site in
3 pieces and assembled on site. The verification activity
would typically be inspection of the erected major plant item,
pressure testing etc.
3.3 Construct Piping
Install pipework as defined by the detailed piping design
specifications, and verify that the design has been satisfied.
The verification activity would typically be inspection of the
piping, pressure testing etc.
3.4 Install Electrical and Instrumentation Systems
Install electrical and instrumentation equipment as defined by
the detailed electrical and instrumentation design
specifications, and verify that the design has been satisfied.
The verification activity would typically be electrical and
instrument loop testing, off line testing of the trip system and
control system etc.
 3.5 Complete Special Finishes, Linings, Thermal Insulation Prepare the equipment for commissioning. This would
And Painting include packing the vessels with non feedstock material,
Implement finishes, linings, thermal insulation and painting including flow dispersers, catalyst etc.
as defined by the detailed design specifications, and verify 5.3 Perform Precommissioning Tests
that the design has been satisfied. Test the individual items of equipment before inert or process
fluids are introduced, e.g. testing pump motors etc.
4. Produce As Built Surveys 5.4 Perform Baseline Inspection
Survey the finished construction work in order to identify non Perform the baseline inspection of e.g. pressure systems
conformance with the detail design specifications, and update
the design specifications with the design changes implemented 6. Handover to Process Commissioning
during construction. Transfer responsibility for the plant from the construction team to
4.1 Perform Conformance Checks the commissioning team, documented by a Handover Certificate.
Survey the finished construction work in order to identify
non conformance with the detail design specifications that
need resolution.
Reference may be made to the verification records for the
construction activities and inspection data for bought in
major plant items, e.g. records of pressure testing vessels etc.
4.2 Produce As Built Specifications & Drawings
Update the detailed design specifications and drawings with
the approved design changes implemented during
construction.
4.3 Identify Unfinished Work
Identify any unfinished work and allocate responsibility for
its completion.

5. Pre Commission
Prepare the plant for commissioning.
5.1 Clean Plant for Testing and Commissioning
Clean and flush the plant in preparation for testing and
commissioning.
5.2 Prepare Equipment for Commissioning
30
PRODUCE
OPERATE
DETAILED
PROCESS
COMMISSION PROCESS & HANDOVER PLANT PLANT
DESIGN
Produce Train Perform
Commission Handover
Commissioning Commissioning Acceptance
Plant Plant For
Plan Personnel Testing Operation

Perform Trip Identify Plant Update Operating

Tests Performance Procedures
Envelope As Built Drawings
Finalize Operating Procedures
Perform Cold
Acceptance Test results
Commissioning Compare Agreement
Handover Certificate
Performance to With Regulatory
Perform Hot Specification Bodies
Commissioning
Identify Corrective Perform Plant
Tune Control Actions & Handover
Systems Responsibility

CONSTRUCT &
PRE-COMMISSION
PLANT
P Harrow colact1 ©PISTEP 26/04/94

31
 COMMISSION PROCESS & HANDOVER PLANT

Prove operation of all plant systems as defined by the detailed design specifications such that the plant can be accepted for operation to manufacture
product.
Commissioning typically consists of a number of stages progressing from activities using either non or inert process materials to the use of production
process materials.

1. Produce Commissioning Plan 3.2 Perform Cold Commissioning

Produce a commissioning plan which identifies all
commissioning activities, their time and resource requirements
and dependencies.
2. Train Commissioning Personnel
Train personnel to commission the plant.
3. Commission Plant
Prove operation of the plant as defined by the detail design
specifications by the introduction of process materials into the
plant and operating the plant to prove the process transforms
feedstocks to products.
3.1 Perform Trip Tests
Prove operation of the plant safety trip system as defined by
the detail design specifications.
The trip test would use as far as practicable real process
conditions to cause trip detection with use of simulation via
instrument signal injection only on limited cases. For
example level trips would be tested by introducing a liquid
into the vessel.
Prove operation of the plant as defined by the detail design
specifications by the introduction of inert feedstock materials
into the plant and performing the unit operations designed to
effect transformation into product or products.
3.3 Perform Hot Commissioning
Prove operation of the plant as defined by the detail design
specifications by the introduction of production feedstock
materials into the plant and operating the plant to prove the
process transforms feedstocks to products.
3.4 Tune Control Systems
Tune the control loops within the control system for the
plant.
4. Perform Acceptance Testing
Test the plant under operating conditions to ensure that it
conforms to the design specification and obtain the performance
envelope for the plant.
4.1 Identify Plant Performance Envelope
Operate the plant under various conditions to determine the
operating range for the plant.
4.2 Compare Performance to Specification
Compare operation with the detail process design
specifications.

32
 4.3 Identify Corrective Actions & Responsibility
Identify any corrective actions required to make the plant
perform to specification and the allocate responsibility for
those corrective actions.

5. Handover Plant for Operation

Transfer responsibility for the plant from the commissioning
team to the operating team, documented by a handover
certificate.
5.1 Update Operating Procedures
Update the operating procedures to incorporate changes that
may have occurred during construction and commissioning.
5.2 Finalise Agreement with Regulatory Bodies
Obtain the final agreement with the regulatory bodies that all
relevant regulations have been met and that the plant may be
put into operation.
5.3 Perform Plant Handover
Produce the handover certificate and hand the plant over to
the operating staff for operations.

33
COMMISSION PROCESS
& HANDOVER PLANT
OPERATE PLANT DECOMMISSION
PLANT

Plan &
Ensure Request and
Schedule Operation
Safe Plant Approve Work
Plant Of Plant
Operation on Plant
Operation

Obtain Operating Define Configure Plant Identify

Procedures Operating Modes Requirement Plant Status
Start-up Plant for Engineering Ground Drains Status
Obtain Operating Plan Plant Work Safety Case
Schematics Operations Monitor Plant As Built & As Modified Drawings
Performance Request
Define Safety Schedule Plant Engineering Work
And Security Operations Optimize Plant
Procedures Performance Approve Work
Permits
Obtain Certificate Account for Plant
to Operate Performance Ensure Safe
Working
Maintain Safety Shutdown & Conditions
Case Clean Out Plant
Accept
Train Operating Dispose of Engineering
Personnel Inventory Work

Engineering Work Requests

Working Conditions Requirements
Engineering Work Permits
Acceptance of Engineering Work

MAINTAIN
EQUIPMENT

P Harrow colact1 ©PISTEP 26/04/94

34
 OPERATE PLANT

Operate plant safely, efficiently, and according to plan.

1. Ensure Safe Plant Operation

Take those steps necessary to ensure that the plant can be 2.1 Define Operating Modes
operated in a safe and proper manner. Identify and define the standard ways in which the plant
1.1 Obtain Operating Procedures should operate so that plans can be based on these standard
Acquire Operating Procedures from the Process Design team. operating modes.
1.2 Obtain Operating Schematics 2.2 Plan Plant Operations
Acquire Operating Schematics from the Process Design Plan for the longer term and in restricted detail the way the
team. plant should operate.
1.3 Define Safety and Security Procedures 2.3 Schedule Plant Operations
Define the procedures that will ensure that the plant is Plan in detail the operation of the plant in the immediate
operated in a safe manner at all times, and that the security of future.
the plant is not breached at any time.
1.4 Obtain Certificate to Operate 3. Operation of Plant
Acquire the certificate to operate the plant and ensure that it Operate the plant to produce products in a safe, efficient and
properly reflects the use of the plant. effective manner.
1.5 Maintain Safety Case 3.1 Configure Plant
Ensure that the safety case for the plant properly reflects the Line-up the plant choosing which circuits to use from the
state and operation of the plant, and to revise the safety case available options.
when this is appropriate. 3.2 Start-up Plant
1.6 Train Operating Personnel Prepare the plant for the introduction of feed. Introduce the
Train the personnel in the procedures that will ensure that the feed, and bring the plant up to normal operating conditions.
plant is operated in a safe and efficient manner at all times, 3.3 Monitor Plant Performance
and that the security of the plant is not breached at any time. Measure process conditions, and summarise as appropriate
for reporting purposes.
2. Plan and Schedule Plant Operations 3.4 Optimise Plant Operations
Plan the way that the plant will operate in future periods.

35
 Check plant performance conforms to target performance, Check that work has been satisfactorily completed before
and take corrective action where necessary. making plant available for operation.

3.5 Account for Plant Performance

Create formal record of plant performance for accounting
purposes.
3.6 Shut-down & Clean Out plant
Reduce operating conditions and feedstock flowrates in such
a way as to safely bring the plant out of operation. Clean out
plant to remove any remaining feedstocks.
3.7 Dispose of Inventory
Remove feedstocks and other reagents from the plant.

4. Request and approve Work on Plant

Request maintenance. Approve proposed maintenance work.
Make sure work is carried out safely, and sign-off completed
work.
4.1 Identify Requirement for Engineering Work
Identify the need for engineering work when equipment does
not work or fails to operate as expected.
4.2 Request Engineering Work
Define priority of maintenance requirements and request that
they are carried out.
4.3 Approve Work Permits
Ensure that the way work is proposed to be carried out is
safe.
4.4 Ensure Safe Working Conditions
Ensure that conditions are safe whilst work is carried out, e.g.
no flammable materials in area if hot work is being carried
out.
4.5 Accept Engineering Work

36
BLANK PAGE

37
 OPERATE
PLANT
Inspection Requirements
Work Permit Requests
Notification of Work Completion

MAINTAIN EQUIPMENT
CONSTRUCT & Plan Actual Prepare For Maintain
Define DEMOLISH PLANT
PRE-COMMISSION Maintenance Maintenance Maintenance Or
PLANT Or Or Inspect
& RESTORE SITE
Approach
Inspection Inspection Equipment

Obtain Plant Availability Respond to Maintenance Obtain Equipment Prepare Site

Requirements Request Records for Work
Obtain Equipment Identify Routine Obtain Plant & Perform
Records Maintenance Requirement Equipment Drawings Maintenance State of Equipment
or Inspection Value of Equipment
Obtain Plant & Identify Inspection Obtain Maintenance Equipment Records
Equipment Drawings Requirements Procedures Record
Resources
Obtain & Develop Obtain Equipment Records Obtain Resources Consumed
Maintenance
Procedures Obtain Plant & Equipment Obtain Work Permits Update
Drawings Equipment
Define Preventative, Obtain Inspection Records
Breakdown, Shutdown Obtain Maintenance Reports
Maintenance Strategy Procedures
Obtain & Develop Spares Obtain Plant Availiability
Strategy Requirements
Obtain Hazardous Identify Resource
Materials Data Requirements
Train Maintenance & Schedule Maintenance
Inspection Staff & Inspection

Materials & Equipment Requirements & Specifications

Required on Site Dates

PROCURE & CONTROL

EQUIPMENT, MATERIALS
& SERVICES
P Harrow colact1 ©PISTEP 10/06/94

38
 MAINTAIN EQUIPMENT
Maintain plant and equipment in a safe manner to ensure plant operability.
1. Define Maintenance Approach
Define the approach to the task of maintaining plant and
equipment.
1.1 Obtain Plant Availability Requirements
Obtain the plant availability requirements which the
maintenance must achieve.
1.2 Equipment Records
Obtain the records for each item of equipment in the plant.
1.3 Obtain Plant and Equipment Drawings
Obtain the drawings for the plant and each item of equipment
in the plant.
1.4 Obtain and Develop Maintenance Procedures
Procedures provide information for performing tasks relating
to routine, preventative, inspection and corrective
maintenance activities. The procedures will have to be
developed as the plant is modified or the need for new
procedures arise.
1.5 Define Preventative, Breakdown, Shutdown Maintenance
Strategy
Define the strategy to be followed for preventative
maintenance and maintenance required as the result of
breakdown or shutdown.
1.6 Obtain and Develop Spares Strategy
Obtain the spares strategy developed during the Detailed
Engineering Design and develop this to meet the needs of the
plant and equipment.
39
1.7 Obtain Hazardous Materials Data
Obtain the data relating to the storage, handling and disposal
of hazardous materials issued by Regulatory Bodies, or
others.
1.8 Train Maintenance & Inspection Staff
Train staff in inspection and maintenance procedures so that
the equipment is inspected and maintained in a safe and
timely manner.
2. Plan Actual Maintenance or Inspection
Plan the sequence of operations required to perform inspection
or maintenance of equipment.
2.1 Respond to maintenance Request
Identify the manpower, materials, special resources, estimate
costs and Work Permits required to meet the maintenance
request.
2.2 Identify Routine Maintenance Requirement
Identify requirements for routine maintenance for equipment
based on the maintenance approach and procedures for the
equipment.
2.3 Identify Inspection Requirements
Identify inspection requirements for equipment based on the
maintenance approach and procedures for the equipment.
2.4 Obtain Equipment Records
Obtain the records for each item of equipment to be
maintained or inspected.
 2.5 Obtain Plant and Equipment Drawings
Obtain the drawings for the plant and each item of equipment
in the plant to be maintained.
2.6 Obtain Maintenance Procedures
Obtain the procedures which provide information for
performing tasks relating to routine, preventative, inspection
and corrective maintenance activities.
2.7 Obtain Plant Availability Requirements
Obtain the plant availability requirements which the
maintenance must achieve.
2.8 Identify Resource Requirements
Identify the resources in personnel, spares and special tools
required to perform the maintenance or inspection.
2.9 Schedule Maintenance & Inspection
Schedule the maintenance or inspection required.
3. Prepare for Maintenance or Inspection
Prepare to carry out the required maintenance or inspection.
3.1 Obtain Equipment Records
Obtain the records for each item of equipment to be
maintained or inspected.
3.2 Obtain Plant and Equipment Drawings
Obtain the drawings for the plant and each item of equipment
to be maintained.
3.3 Obtain Maintenance Procedures
Obtain the procedures which provide information for
performing the maintenance or inspection.
3.4 Obtain Resources
Obtain the resources in personnel, spares and special tools
required to perform the maintenance or inspection.
3.5 Obtain Work Permit
40
Obtain authorisation to allow work to be executed and the
conditions that must be fulfilled to perform the work safely.
3.6 Obtain Inspection Report
The inspection report records the results of the last inspection
of an equipment item with details of conditions inspected e.g.
Test Pressure.
4. Maintain or Inspect Equipment
Prepare the site and perform the required maintenance or
inspection.
4.1 Prepare the site for work
Perform any preparatory work on the site before undertaking
maintenance or inspection.
4.2 Perform Maintenance or Inspection
Perform the required maintenance or inspection.
4.3 Record Resources Consumed
Provide a record of resources in labour and spares consumed
in performing the maintenance activities.
4.4 Update Equipment Records
Update the records of activities and work completed on the
equipment.
BLANK PAGE

41
 DECOMMISSION PLANT

Produce
OPERATE Define Decommissioning Perform Clean &
PLANT Decommissioning & Restoration Preparatory Mothball
Requirements Plan Works Plant

Identify Current Isolate Services Clean Plant

Status
Provide Mothball Plant
Define Final Temporary Services
Status Archive Plant
Provide Records
Decommissioning
Equipment Determine
Inspection
Requirements

Finalize
Regulatory
Approvals

Plant Status
Plant Records
Inspection Requirements
Regulatory Approvals

DEMOLISH PLANT
& RESTORE SITE

P Harrow colact1 ©PISTEP 24/04/94

42
 DECOMMISSION PLANT

Take a plant out of operating service, isolate all feedstock and services, remove all process materials from the plant, and establish maintenance
conditions such that the plant could be returned to operating service.

1. Define Decommissioning Requirements 4. Clean And Mothball Plant

Identify the current plant status and define the required mothball Clean the plant and establishing any maintenance conditions
plant status. such that the plant could be returned to operation.
1.1 Identify Current Status 4.1 Clean Plant
Identify the current plant status. Clean the plant internally and externally prior to mothballing.
1.2 Define Final Status 4.2 Mothball plant
Define the final plant status. Put the plant in a state such that its condition is preserve so
that the plant could be returned to operation or demolished.
2. Produce Decommissioning & Restoration Plan 4.3 Archive Records
Produce a decommissioning plan which identifies all The archiving of all records associated with the plant to meet
decommissioning activities, restoration activities and their time regulatory requirements or recommissioning requirements.
and resource requirements and dependencies. 4.4 Determine Inspection Requirements
Determine any inspection requirements from regulatory
3. Perform Preparatory Works bodies.
Undertake preparatory works required before the plant may be 4.5 Finalise Regulatory Approvals
cleaned and mothballed. Finalise any agreements with regulatory bodies that the plant
3.1 Isolate Services site has met all requirements.
Isolate power and other services from the plant.
The isolation would typically be electrical power, instrument
and process air, steam, cooling water etc.
3.2 Provide Temporary Services
Provide temporary services required during the cleaning and
mothballing of the plant.
3.3 Provide Decommissioning Equipment
Provide decommissioning equipment required to clean and
mothball the plant.

43
 DECOMMISSION PLANT

DEMOLISH PLANT AND RESTORE SITE

Define
MAINTAIN Demolition & Plan Prepare
Demolish & Restore Dispose of
EQUIPMENT Restoration Demolition for Plant
Secure Plant Site Site
Requirement & Restoration Demolition

Define Produce Obtain Equipment Prepare Site Survey Site Archive Records
Demolition Demolition Records Contamination
Requirements Procedures Remove Finalize
Obtain Plant & Plant Remove / Treat Regulatory
Define Produce Resource Equipment Drawings Contaminated Approval
Restoration Estimates Dispose of Material
Requirements Obtain Maintenance Plant
Produce Procedures Dispose of
Perform Safety & Demolition & Box up & Contaminated
Environment Study Restoration Obtain Resources Secure Plant Material
Plan To Remain
Obtain Work Permits Restore
Environment
Obtain Inspection
Reports

Disposal Records
Restoration Records
Handover Records
Final Regulatory Approvals

P Harrow colact1 ©PISTEP 26/04/94

44
 DEMOLISH PLANT AND RESTORE SITE

The activity of taking a plant out of operating service, isolating all feedstock and services, removing all process materials from the plant, and
establishing maintenance conditions such that the plant could be returned to operating service.

1. Define Demolition & Restoration Requirement
Identify the current plant and equipment status, the demolition
and restoration requirements and any hazards involved in
implementing demolition.
1.1 Define Demolition Requirements
Identify demolition requirement for the plant.
1.2 Define Restoration Requirements
Identify the restoration requirement for the plant.
1.3 Perform Safety & Environment Study
Perform a safety and environment study to ensure that the
plant may be demolished in a safe manner without hazard to
personnel or the environment.
2. Plan Demolition And Restoration
Identify the current plant status and produce the demolition and
restoration plans.
2.1 Produce Demolition Procedures
Identify any hazards involved with the demolition and
restoration activities and define procedures to manage them
in a safe manner.
2.2 Produce Resource Estimates
Produce estimates for the resources required for the
demolition or restoration of the plant.
2.3 Produce Demolition And Restoration Plan
Produce a demolition and restoration plan which identifies all
demolition and restoration activities, their time and resource
requirements and dependencies.
3. Prepare Plant For Demolition
Prepare the plant for demolition.
3.1 Obtain Equipment Records
Obtain the records for each item of equipment to be
demolished.
3.2 Obtain Plant and Equipment Drawings
Obtain the drawings for the plant and each item of equipment
to be demolished.
3.3 Obtain Maintenance Procedures
Obtained the procedures which provided information for
performing the maintenance or inspection of the equipment
to be demolished.
3.4 Obtain Resources
Obtain the resources in personnel, spares and special tools
required to perform the demolishment of the equipment.
3.5 Obtain Work Permit
Obtain an authorisation for work and the conditions
necessary for it to be carried out safely.

45
 3.6 Obtain Inspection Reports Transfer responsibility for the plant from the demolition team to
Obtain the inspection report that gives the state of equipment the site owner, documented by a handover certificate.
items with details of conditions inspected e.g. Test Pressure. 6.1 Archive records
Archive all records associated with the demolition and
4. Demolish And Secure Plant restoration of the site.
Demolish, remove and dispose of plant. Secure plant to remain. 6.2 Finalise Regulatory Approval
4.1 Prepare Site Obtain regulatory body approval that the site has been
Prepare the site for demolition of the plant. correctly restored and is fit for disposal.
4.2 Remove Plant
Remove from site the demolished plant.
4.3 Dispose of Plant
Dispose of plant items and materials.
4.4 Box-Up And Secure Plant To Remain
Establish any maintenance conditions for plant to remain on
site.

5. Restore Site
Restore the site to meet environmental requirements or prepare
the site for new plant.
5.1 Survey Site Contamination
Perform a survey of site contamination.
5.2 Remove / Treat Contaminated Material
Remove or treat material from the site which may prove a
hazard subsequent to the restoration of the site.
5.3 Dispose of Contaminated Material
Dispose of any contaminated material in a safe and approved
manner.
5.4 Restore Environment
Restore the site to a condition approved by regulatory bodies.
Typical activities here would be reset drains, landscaping etc.

6. Dispose of Site
46