PLANT/FACILITIES ENGINEERING

Definition and Description of Functions and Responsibilities

Approved by the Board of Directors of The AFE Foundation

REVISION STATEMENT The plant/facilities engineering function within the industrial, commercial, institutional, and business communities represents a field of work that is continuously changing. The ever-increasing demands placed upon the plant/facilities engineer warrant an ongoing review of those functions and responsibilities. This review process was conducted under the direction of the Board of Directors of the AFE Foundation by the following: Chairman, AFE Foundation: Richard L. Dunn, Editor, Plant Engineering Magazine Project Coordinator: Norwood G. Woody Nelson, FAFE, Retired, Past President AFE (AIPE) Principal Editor: Richard L. Dunn, Editor, Plant Engineering Magazine Reviewers: John Blumenshine, PE/CPE, Vice President-Facilities, S & C Electric Co.

ACKNOWLEDGMENT The original plant engineers code, a 1925-28 project of the Plant Engineers Club of Boston, was developed by a committee headed by Kenneth D. Hamilton. That work constituted the source for the 1959 revision by a committee chaired by James T. Snow. The revision became the model for a version created in 1994 by Leon R. Martin, CPE, and Theodore D. Malloy, CPE. The current document, modeled on the previous versions, but substantially revised, was approved in December 1997 and subsequently updated in December, 2002. AVAILABILITY Copies of this document are available from: The AFE Foundation 12801 Worldgate Drive Suite 500 Herndon, Virginia 20170

PLANT/FACILITIES ENGINEERING AS DEFINED BY THE AFE FOUNDATION

PREFACE While many functions and responsibilities within plant/facilities engineering are nearly universal, there are substantial differences from industrial to commercial to institutional, and other businesses. This document intends to embrace all of those differences, but the authors recognize that it can be neither completely inclusive nor exclusive. Both the names plant engineering and facilities engineering are in widespread use. And while some may prefer the nuances of one name over another, they are for all practical purposes interchangeable; thus, the usage throughout this document of plant/facilities engineering. DEFINITION Plant/facilities engineering is a multidisciplinary field of engineering concerned with the physical infrastructure of industrial, commercial, institutional, healthcare, and business facilities. It embraces the design, installation, operation, maintenance, modification, construction, modernization, and protection of physical facilities and equipment used to produce a product or provide a service. It includes, but is not necessarily limited to, the following areas of management: Design of facilities and systems Construction of facilities and systems Installation of facilities and systems Start up of systems Operation of systems Maintenance of facilities and systems Retrofit of facilities and systems Environmental controls Safety and health Security and fire protection Production processes and equipment (in industry) Regulatory compliance (local, state, and federal) Energy management and building control . Energy supplies & contracts in a deregulated market Administration, supervision, organization, planning Other support functions as required by the facility owner or manager.

KNOWLEDGE BASE Individuals in plant/facilities engineering must continually demonstrate professional competency in assuming liaison or control responsibility for coordinating multidisciplinary engineering activities while interacting with all other elements of the

organization. The complexity of the plant/facilities engineer position is such that no single engineering science comprises all its needs. The practice of plant/facilities engineering at a professional level in its full range of duties requires the individual to have an understanding of, and proficiency in, the following subject areas: Electrical systems Circuit planning Power distribution Illumination Protective devices Testing Instrumentation and control Electrical machinery On-site power & co-generation Codes and standards Mechanical systems Heating, ventilating, air conditioning, and refrigeration Steam/water/sewer & process piping Pumps, piping, and plumbing Compressors and compressed air systems Power transmission Material handling and storage Fire protection Instrumentation and controls Codes and standards Civil and structural Drainage & stormwater management Materials specification Structural design and analysis Construction practices Building and life safety codes Maintenance Systems reliability Understanding and interpretation of drawings and specifications Lubrication Maintenance programs and management Preventive and predictive maintenance practices Maintenance supplies, stores, and inventory management Buildings and grounds Housekeeping Welding and joining Economics

Industrial equipment specification and selection Estimating Budgeting and forecasting Strategic planning Energy management Purchasing Financial management Administration and supervision Organization and manpower planning Personnel development Business law Labor relations Project administration and management Security services Record keeping Environmental, safety, and health management Noise control Air quality control Water quality control Solid waste handling Hazardous materials control Regulations, codes and standards Life safety, security, and fire fighting systems The plant/facilities engineer must have major knowledge emphasis in mechanical, electrical, civil, and/or architectural engineering skills. A basic general knowledge of the remaining engineering sciences is a necessity for a solid educational base to build on. The plant/facilities engineer must continue to gain education to forward his/her professional knowledge and strengthen the company in which he/she is employed through continuing formal and informal education, seminars, conferences, and other sources.

GENERAL DESCRIPTION OF FUNCTIONS AND RESPONSIBILITIES The plant/facilities engineering department in any enterprise is multifunctional. Because of this diversity, the reporting procedure and the direct responsibilities should be clearly defined. Reporting The plant/facilities engineering director should report directly to the general manager, unit manager, president, CEO, owner, or whoever makes the final decision on any

project, capital expenditure, legal concern, or enterprise policy decision. If in a multisite structure with a corporate engineering department, the plant/facilities engineer should report directly to the site manager with secondary reporting responsibility to the director of corporate engineering. General Responsibilities The plant/facilities engineering manager should be responsible for: Directing and coordinating the operations and activities of plant/facilities engineering administration, engineering, layout, design, construction, utilities operations and maintenance, building and grounds maintenance, plant protection and security, equipment maintenance, environmental, and safety Providing engineering consulting services, surveys, and recommendations to all departments of the complex; to outside architect-engineer firms performing services for the complex; and to public utilities Ensuring compliance with applicable federal, state, and local laws, regulations, statutes, and codes; securing all required permits; and coordinating with appropriate local authorities Contracting with and overseeing the activities of various contractors and consultants for the fulfillment of plant/facilities engineering responsibilities.

FUNCTIONS OF THE PLANT/FACILITIES ENGINEERING DEPARTMENT Every company, business, or corporation has created its own distinct responsibility assignments for each department. The following outline is intended to help define and understand the specific functions, operations, and activities that may be required of a plant/facilities engineer and engineering department. Administration Administrative operations of the plant/facilities engineering department include: Program coordination for the plant/facilities engineering department and liaison with all other departments for the procurement and maintenance of all real property, production equipment, utilities services, and communications services Preparation of plant/facilities engineering department budgets Proposal, justification, and management of capital projects and expenditures Maintenance of records of planned and current construction and maintenance contracts Review and filing of reports from inspectors and insurance carriers, and preparation of status reports to appropriate management Processing of work requests; preparation of project cost estimates; planning and scheduling of work; provision of required parts, materials, and equipment; and maintenance of all related labor and equipment records Management of parts, materials, and equipment for which the plant/facilities engineering department is held accountable Preparation of appropriate reports, statistics, and recommendations on plant/facilities engineering activities Solicitation, preparation, and administration of appropriate contracts

Planning, coordination, and scheduling of predictive and preventative maintenance programs for structures, utilities, and equipment (including production equipment in industrial plants) Maintenance of appropriate records pertaining to labor under the jurisdiction of the plant/facilities engineering department Assuring that department personnel are licensed, registered, or certified as appropriate.

Engineering, Layout, and Design Engineering, layout, and design activities of the plant/facilities engineering department include: Furnishing engineering, designs, specifications, bills of materials, and cost estimates for construction and major rehabilitation of all real property and for major projects of installation and relocation of equipment Continual review and evaluation of utility, building, and structural requirements and preparation of projects as required Acting as technical liaison for design engineering projects of collateral interest with other departments Maintaining a master plan for improvement and expansion of the plant/facilities Preparation of designs, layouts, drawings, and bills of materials for major maintenance, plant/facility improvement, and other projects Maintenance of current as built drawings and files for all plant/facility structures, systems, equipment, etc. Provision of technical/engineering support to other departments regarding process and/or equipment changes Maintenance of all real property records. Construction Plant/facilities construction operations and activities that may be required of a plant/facilities engineer and engineering department include: Preparation or oversight of the architectural, structural, mechanical, electrical, utilities, site, environmental design, and other construction and engineering drawings for all facilities Evaluation and selection of construction contractors Oversight and project management of all construction work and approval after completion. Plant/Facilities Protection Plant/facilities protection operations and activities that may be required of a plant/facilities engineer and engineering department include: Training of designated plant personnel in fire fighting and emergency response. Training of personnel in all phases of operation and maintenance of emergency response apparatus and fire extinguishing systems. Conduct of emergency evacuation drills Regularly inspecting buildings, fire fighting equipment, fire protection systems, and areas to detect and eliminate fire, safety, health and security hazards Assuring compliance with all applicable life safety and building codes and regulations

Design, installation, and maintenance of all plant/facility fire protection and security systems Specification, installation, and maintenance of all fire protection and security equipment Formulation of all emergency response and recovery plans for all areas of the plant or enterprise Provision of first-response capability for all life-threatening and property-threatening emergencies Providing assistance in investigation of fires and other emergencies to determine cause and take corrective/preventive action Maintaining liaison with local community emergency-response and law-enforcement organizations for assistance as required Maintenance of all required records for OSHA and other regulatory agencies Establishment of practices regarding handling and disposal of classified materials Conduct of necessary security checks, inspections, surveys and investigations to assure that the required standards of physical security are maintained. Establishment and operation of employee and visitor control identification systems. Control of security cards and keys for buildings, structures and equipment; maintenance of vaults, safes, and locked files. Utilities Operation & Energy Management Utilities operations and energy management responsibilities that may be required of a plant/facilities engineer and engineering department include: Operation and maintenance of all utilities systems and equipment in the plant/complex Completion of operating logs, reports, and records required by federal, state, and local agencies and the company Compliance with all applicable federal, state, and local codes, statutes, and regulations Development of energy management and conservation programs Liaison with public utilities Procurement of fuels and energy Specifying, operating, and maintaining of backup utility systems. Maintenance Management The maintenance operations and activities that may be required of a plant/facilities engineer and engineering department include: Installation and maintenance of all utilities systems and components for electricity, water, steam, gas, oil, compressed air, communications, data networks, etc. Provision of services for construction, alterations, maintenance, and repair of buildings and structures Installation, operation, and maintenance of all heating, ventilating, air conditioning, and refrigeration systems and components Installation, relocation, modification, maintenance, and repair other equipment and systems as determined by coordination with other departments Testing of electrical & utility back-up systems Maintenance of appropriate equipment records and histories

Management of maintenance planning, scheduling, and work execution Implementation of preventive and predictive maintenance strategies and practices Management of spare parts and materials storerooms and inventories Coordination of federal, state, local, and insurance licensing inspections and compliance Management of special projects as required Provision of housekeeping, janitorial, and custodial services

Environmental Stewardship The environmentally related operations and activities that may be required of a plant/facilities engineer and engineering department include: . Champion waste minimization efforts throughout operations Initiation of all requests for air quality, water quality, stormwater discharge, hazardous material, and solid waste disposal permits pertaining to the facility and all equipment contained within it to meet federal, state, and local requirements Coordination and supervision of all monitoring required to meet federal, state, and local regulations Maintenance of all environmental permits and recordkeeping required to operate the facility and equipment on site Formulation of contingency and emergency response plans and training of personnel for control, containment, cleanup, and disposal of hazardous and nonhazardous spills Management of environmental monitoring activities Correction of environmental deficiencies Notification of appropriate regulatory agency representatives of any and all occurrences that deviate from compliance guidelines and laws. Safety The safety operations and activities that may be required of a plant/facilities engineer and engineering department include: Organization, administration, and supervision of safety activities in accordance with all federal, state, and local requirements Instruction and training of employees in safety requirements and procedures for the facility, its equipment and systems Conduct of regular periodic safety inspections of buildings, grounds, production equipment, utilities equipment and services, etc. Maintenance of records of training and inspections pertaining to safety as required by federal, state, and local authorities Initiation of safety-related work requests Compliance with all safety procedures. Contracts The contracting operations and activities that may be required of a plant/facilities engineer and engineering department include: Review and approval of all bids and submissions for plant/facilities contract work Preparation, in coordination with legal counsel, of all major contracts for engineering work, technical specifications, purchase of equipment, and the erection and maintenance of structures; approval of all such plans, specifications, and contracts before their award

Representation of the owners interests in all relevant contracts either written or implied, interpretation of the responsibilities of principal and agent, and evaluation of the performance of engineering work regulated by contracts and specifications Project management and completion of all construction contracts according to plans and specifications. Insurance The insurance operations and activities that may be required of a plant/facilities engineer and engineering department include: Working with insurers on engineering problems, inspections, and corrections to reduced hazards and rates. Conduct of periodic inspections of the plant to cover all departments to maintain a recommendation-free environment. Maintaining appropriate knowledge of rules and regulations of insurers Coordination of construction and other projects with insurance carriers. RELATIONS WITH OTHER DEPARTMENTS AND SERVICES A major activity of the plant/facilities engineer and engineering department is building and maintaining relations with other company departments and outside services. As a primarily service/support organization, the plant/facilities engineering department must coordinate with and respond to the needs of other departments. The following outline provides guidance on the organizational relationships between the plant/facilities engineering department and other departments and services. Plant/Facility and Company Management The plant/facilities engineering department should ensure that plant/company management is kept thoroughly informed on all matters that are the responsibility of the plant/facilities engineering department, especially matters concerning the following: value of assets, insurance, environmental compliance, safety, permits, regulations, and ability of the plant/facility to produce products or provide services. The plant/facilities engineering department should report periodically to management on work accomplished, work in process, status of conditions under its control, and work anticipated. These reports should include comments and recommendations as appropriate. Production Department The plant/facilities engineering department should not assume responsibility for production scheduling, quantity, or quality, but it should work closely with the production department in supporting production goals. In liaison with the production department, the plant/facilities engineering department should provide and maintain equipment for production and be responsible for problems related to such concerns as speeds of operation, temperature, voltage, pressures, process control instrumentation, machine communications, and general up-time and efficiency of machinery. The plant/facilities engineering department should work with and support the production department on the design, installation, and maintenance of production

systems and equipment and should advise on the safe and economical operation of such equipment. As part of its overall responsibility for plant and equipment maintenance, the plant/facilities engineering department should work with production personnel on maintenance training, scheduling, and procedures for production equipment Accounting Department The plant/facilities engineering department should coordinate with the accounting department for establishing appropriate accounts for such classifications as the plant/facilities engineering department may require. The plant/facilities engineering department should define the classification of any labor or materials used on any work performed under its supervision. The plant/facilities engineering department should be consulted as to life of any building or equipment in connection with depreciation evaluation. The plant/facilities engineering department should approve all payments to contractors and contract engineers for work done under its auspices. The accounting department and the plant/facilities engineering department will cooperate in the preparation of figures for the distribution of expenses for facilities operations to each department. The plant/facilities engineering department should work with accounting concerning records and procedures for maintenance and operations storerooms and stores inventories. The plant/facilities engineering department should conduct periodic capital asset inventories for accounting purposes. Purchasing Department The plant/facilities engineering department should generate all specifications for, and approve all materials and equipment furnished in response to, its requisitions. Major or specialized equipment should be specified and selected by the plant/facilities engineering department in cooperation with purchasing, production, or other involved departments. Information regarding relevant suppliers and sources should be shared between the plant/facilities engineering and purchasing departments. Purchasing policies concerning authority to specify products, materials, sourcing, etc., should be worked out cooperatively between the plant/facilities engineering and purchasing departments. Authority to purchase in emergency or downtime situations should be given special attention. The plant/facilities engineering department should prepare contracts and specifications and review with the purchasing department all bids on equipment, construction, power purchases, or other allied services in compliance with the companys internal audit regulations. The plant/facilities engineering department will check and report all goods received on its orders for quantity and quality, and should make such tests as are necessary and report to the purchasing department when requested as to the results obtained. Consultants

The plant/facilities engineering department should have authority to contract with consultants when additional professional or technical advice is necessary or appropriate. All plant/facilities engineering data furnished to consultants should be provided by or approved by the plant/facilities engineering department. Any plant/facilities engineering work done by a consultant should be subject to the review and approval of the plant/facilities engineer.

Legal Counsel The plant/facilities engineering department should obtain the advice of legal counsel on all special problems pertaining to law. The plant/facilities engineering department should coordinate with legal counsel on all matters pertaining to land, water, and air rights. The plant/facilities engineering department should inform legal counsel of all issues relating to usage, storage, and disposal of hazardous and controlled substances. The plant/facilities engineering department should coordinate with legal counsel concerning intellectual property rights under its jurisdiction. The plant/facilities engineering department should consult with legal counsel on all code, environmental, safety, and other regulatory demands or visits. Human Resources The plant/facilities engineer should work with the human resources department in preparing hiring, testing, and training guidelines and requirements for employees in the plant/facilities engineering department. The plant/facilities engineering department should work with the human resources department in maintaining appropriate training, certification, and licensing records. Management Information Resources The plant/facilities engineering department will work closely with the IS department on the specification, installation, modification, and maintenance of wiring, power quality, power protection, security, and other related support systems, utilities, and equipment. The plant/facilities engineering department should have responsibility for and oversee the installation and maintenance of fire protection, auxiliary power generation, power quality equipment, power protection equipment, construction, controlled environments, routing, wiring, and fiber optic installation to termination points, in new and existing structures. The plant/facilities engineering department should ensure the continued service of all required utilities at specified conditions to allow proper operation of IS equipment. The plant/facilities engineering department should coordinate with the IS department on computer equipment and software that will impact plant/facilities engineering operations, capabilities, and performance.