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.
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:
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.
4
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
5
OVERVIEW
This diagram gives an overview of the whole life cycle and shows the relationships and data flows for the level 1 activities.
6
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.
7
PRODUCE CONCEPTUAL PROCESS DESIGN
PRODUCE
DETAILED PROCESS
Identify
DESIGN
Define Provide Input to Identify
Candidate Design
Overall 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
8
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.
9
PRODUCE CONCEPTUAL PROCESS DESIGN
PRODUCE
DETAILED
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
10
PRODUCE CONCEPTUAL ENGINEERING DESIGN
Produce the preliminary engineering philosophies to be used and the preliminary engineering design required for further detailed engineering design.
11
3.3 Produce Preliminary Equipment Specifications Produce project plans and budgets for capital and Design and
Generate preliminary specifications for the major electrical Engineering costs.
equipment items. 4.6 Produce Preliminary Weight and Volume Estimates
3.4 Produce Cost and Time Estimates Add weight and volume estimates to the plant list for use in
Produce project plans and budgets for capital and Design and conceptual plant layout and civil/structural design.
Engineering costs. 4.7 Define Commissioning Philosophy
Prepare an outline statement of the rules and sequences for
3.5 Produce Preliminary Weight and Volume Estimates commissioning.
Add weight and volume estimates to the plant list for use in
conceptual plant layout and civil/structural design. 5. Produce Conceptual Safety Engineering Design
3.6 Define Commissioning Philosophy Produce a conceptual safety design that will meet regulatory
Prepare an outline statement of the rules and sequences for requirements and conform to the codes and standards in force.
commissioning. 5.1 Define Safety Philosophies
From the regulatory requirements and the early process
4. Produce Conceptual Control & Instrumentation Engineering definitions, outline the safety criteria appropriate to the type
Design of plant concerned.
Produce the preliminary Conceptual Control and 5.2 Identify Regulatory Requirements
Instrumentation engineering design. Identify the regulatory requirements that govern the siting,
4.1 Identify Materials of Construction construction and operation of the type of plant concerned.
From the process definition, identify appropriate materials 5.3 Define Containment Philosophy
for major process instrumentation and control equipment. From the regulatory requirements and the early process
4.2 Produce Major Equipment Design Philosophy definitions, define the underlying rules for the plant
Prepare an outline statement of the rules and sequences for containment design.
the design of the major equipment. 5.4 Produce Technical Risks Assessment
4.3 Produce Preliminary Equipment Specifications From the developing conceptual design, perform and publish
From the process definition, generate preliminary initial hazard and operability studies.
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. 6. Define Preliminary Plant Layouts
4.5 Produce Cost and Time Estimates
12
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.
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
14
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 4.1 Define Relief & Blowdown Philosophy
Produce schematic drawings detailing equipment, instrument Define the relief and blowdown philosophy to be used in the
and piping connectivity. plant design that will ensure safe and reliable operation of the
plant.
2. Produce Functional Specification for Equipment 4.2 Define Protective System (including Fire) Philosophy
Produce a specification for the functional requirements for all Define the protective systems philosophy for the plant
equipment including process design conditions, material including normal and specialised fire fighting requirements.
specifications, insulation requirements and tracing requirements. 4.3 Define Hazardous Areas
Define the hazardous areas of the plant which may arise due
3. Produce Control Requirements Specifications to the use of toxic substances, radiation, inflammable fluids
Produce the requirements specification for the plant control or gases.
systems. 4.4 Produce Safety & Environment Case
3.1 Identify Control Requirements Produce safety and environmental studies that may be
Identify the specific control requirements for the complete required by regulatory bodies or planning (Zoning)
plant and for each unit operation. authorities.
3.2 Identify Trip Requirements
Identify the alarm, interlock and shutdown requirements for 5. Produce Plant Operating Procedures
the complete plant and for each unit operation. Produce any procedures that may be required for
3.3 Produce Control Requirements Specification Commissioning or Operation of the plant.
Produce a specification detailing the control requirements for
the plant, the alarm interlock and shutdown requirements.
15
PRODUCE DETAILED
PROCESS DESIGN
Produce Detailed Produce Detailed Produce Detailed Produce Detailed Produce Detailed Produce Detailed
Mechanical Produce Building
Electrical Control & Layout & Civil / Structural Safety
Engineering & Plant
PRODUCE Engineering Instrumentation Construction Services Design
Engineering Engineering
Design Design Engineering Design Design
CONCEPTUAL Design Assessment
CONSTRUCT &
ENGINEERING PRE-COMMISSION
Review & Detail Review & Detail Produce Produce Site Survey /
DESIGN Produce Piping & Produce Site
PLANT
Plant / Building Instrumentation Domestic Soil Investigation
Mechanical Layout
Electrical Plant / Building Water,
Equipment Design
Requirements Requirements Sewage & Produce Room / Module
Produce 3D
Produce Equipment Plant Model Storm Water Specifications
Produce Earthing Produce Clean Design
Handling Systems
Requirements Earthing Produce Civil
Design Coordinate
(Static, Requirements Produce Construction
Interfaces
Lightning, Power) Environmental Drawings
Produce Detailed Between Design
Mechanical Produce Areas Control
Produce Measurement Systems Design Containment
Equipment
Communication Instrumentation Design Systems
Specifications Produce Site
System Design Specification Construction &
Define Mechanical Installation Produce Design Process
Produce Electrical Produce Actuator Lighting & Effluent Drainage
Equipment Spares Methodology
Equipment Specifications Small Power Systems
Requirements
Specifications Design
Define Test &
Produce Mechanical Produce Control Pre-Commissioning Design Foundation
Produce Electrical Systems Produce Fire Structures
Maintenance Requirements
Cable Runs Design Specifications Protection
Procedures
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
16
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 2.1 Review & Detail Plant / Building Electrical Requirements
Produce the detailed engineering design for the mechanical Review the electrical requirements received from Detailed
equipment and piping for the plant. Process Design and Conceptual Engineering Design and
1.1 Produce Mechanical & Piping Equipment Design refine to give a detailed list of requirements.
From the equipment data sheets, piping and instrumentation 2.2 Produce Earthing requirements (Static, Lightning,
diagrams and plant layouts, produce detailed procurement Power)
specifications for mechanical equipment items and Produce the requirements for protection of the plant from the
fabrication specifications for piping. build-up of static electricity, lightning protection and
1.2 Produce Equipment Handling System Design earthing of electrical power systems equipment.
From the process facility data and mechanical handling 2.3 Produce Communication System Design
equipment specifications, produce designs for plant Produce the design of any communication systems required
mechanical handling systems. for the operation of the plant.
1.3 Produce Detailed Mechanical Equipment Specifications 2.4 Produce Electrical Equipment Specifications
Produce specifications for all items of mechanical equipment Produce specifications for all items of electrical equipment
on the plant. on the plant.
1.4 Define Mechanical Equipment Spares Requirement 2.5 Produce Electrical Cable Runs Design
Define the spares requirement for all items of mechanical Produce the electrical cable runs design for the plant.
equipment on the plant. 2.6 Produce Power Distribution Systems Design
1.5 Produce Maintenance Procedures Produce the power distribution systems design.
Produce the procedures to effectively maintain all items of 2.7 Produce Electrical Environment Control Requirements
mechanical equipment on the plant. Produce the requirements for environmental control of
electrical equipment on the plant.
2. Produce Detailed Electrical Engineering Design 2.8 Define Electrical Equipment Spares Requirement
Produce the detailed engineering design for the electrical Define the spares requirement for all items of electrical
equipment and cabling for the plant. equipment on the plant.
17
3.8 Define Instrumentation Equipment Spares Requirement
2.9 Produce Maintenance Procedures Define the spares requirement for all items of instrumentation
Produce the procedures to effectively maintain all items of equipment on the plant.
electrical equipment on the plant. 3.9 Produce Maintenance Procedures
Produce the procedures to effectively maintain all items of
3. Produce Detailed Control & Instrumentation Engineering instrumentation equipment on the plant.
Design
Produce the detailed engineering design for the control and 4. Produce Layout & Construction Design
instrumentation equipment and cabling for the plant. From the Equipment design produce the layout and construction
3.1 Review & Detail Instrumentation Plant / Building design
Requirements 4.1 Produce Site Layout Drawing
Review the instrumentation requirements received from From the preliminary civil/structural layouts and the detailed
Detailed Process Design and Conceptual Engineering Design plant layouts, prepare the final site layout drawing.
and refine to give a detailed list of requirements. 4.2 Produce 3D Model
3.2 Produce Clean Earthing requirements From the piping and instrumentation diagrams and
Produce the requirements for clean earths for the preliminary plant layouts, produce the 3D plant model
instrumentation system. incorporating plant structure, piping, ventilation, cabling
3.3 Produce Measurement Instrumentation Specification reservations and plant.
Produce the specification for instrumentation used to 4.3 Co-ordinate Interfaces Between Design Areas
measure process conditions in the operation of the plant. Co-ordinate the interfaces between design areas from
3.4 Produce Actuator Specifications different design sources, to ensure compatibility of all
Produce specifications for all actuators on the plant. aspects of design across the boundaries.
3.5 Produce Control Systems Specification 4.4 Produce Site Construction & Installation Methodology
Produce the control systems specification for the plant. From the 3D layouts, the floor plans/elevations and the
3.6 Define Signal Transmission Pathways developing detailed plant design, produce all layout and
Define the signal transmission pathways required by the construction detail drawings that are necessary to support
instrumentation system. plant construction activities.
3.7 Produce Environmental Control Requirements for 4.5 Define Test & Pre-Commissioning Requirements
Instrumentation Define the test and pre-commissioning requirements for the
Produce the requirements for environmental control of plant.
instrumentation equipment on the plant.
18
5. Produce Plant/Building Services Design From the preliminary plant siting studies, perform physical
From the piping and instrumentation diagrams and preliminary surveys of ground contour, groundwater flow and underlying
plant layouts, produce detailed piping, ventilation and plant geology to support the choice of site.
layouts. 6.2 Produce Room/Module Specifications
From the process facility data, detailed plant layouts and
5.1 Produce Domestic Sewerage and Storm Water Design equipment data sheets, produce the room or module
From the detailed plant layouts and the site layout, produce specifications.
the detail drawings to define the domestic sewerage and 6.3 Produce Civil Construction Drawings
storm water management systems. Produce the drawings for any civil construction work
5.2 Produce Environmental Control Systems Design required.
From the room data sheets, equipment data sheets and the 6.4 Design Containment Systems
detailed plant layouts, produce detailed procurement Implement the containment systems design in civil and
specifications for air-conditioning and other environmental structural design features where appropriate.
control systems. 6.5 Design Process Effluent Drainage Systems
5.3 Produce Lighting and Small Power Design From the detailed process flow diagrams and the detailed
From the room data sheets and the detailed plant layouts, plant layouts, design the necessary collection and storage
produce the layouts and procurement specifications to facilities and pipework to allow the removal of process
support the design and installation of the lighting and small effluents.
power systems. 6.6 Design Foundation Structures
5.4 Produce Fire Protection Systems Design From the preliminary civil/structural weight estimates, the
From the detailed plant layouts and the regulatory site survey data and seismic design criteria, produce the
requirements, produce the layouts and procurement detailed plant foundations designs.
specifications to support the design and installation of the fire 6.7 Produce Painting and Surface Finish Specification
protection systems. Produce the painting and surface finish specification for the
plant and ancillary buildings.
6. Produce Detailed Civil/Structural Engineering Design 6.8 Produce Weight Schedules
From the detailed plant layouts produce the detailed civil and Produce weight schedules for civil / structural items where
structural designs required for the plant. appropriate.
20
Equipment & Materials Catalogues
- Equipment & Materials Specifications
Equipment & Materials Catalogues
- Equipment & Material Availability & Prices
- Equipment & Materials Specifications - Spares Lists
- Equipment & Material Availability & Prices Delivery Dates
- Spares Lists Vendor Drawings
Delivery Dates
Vendor Drawings
Certification
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 Commit Expedite Release for
- Commissioning Procedures Suppliers Evaluate & Issue
Enquiries Purchase Manufacture Inspect Shipment From
- Operating Procedures List Bids Equipment
From Supplier 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
Select & Services Close out Make Unload
SUPPLIERS & Maintain Produce Authorize
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
21
PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES
Make enquiries, place purchase orders, inspect and expedite progress, ship goods and control stock of equipment, and materials.
22
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.
24
COMMISSION PROCESS
& HANDOVER PLANT
As Built Drawings
Equipment Commissioning Procedures
Equipment Operating Procedures
Inspection & Testing Records
Handover Certification
P R O D U C E
D E T A I L E D
MAINTAIN
ENGINEERING CONSTRUCT & PRE-COMMISSION PLANT EQUIPMENT
DESIGN
Complete Special
Finishes, Thermal
Insulation & Painting
25
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.
26
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
27
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
CONSTRUCT &
PRE-COMMISSION
PLANT
P Harrow colact1 ©PISTEP 26/04/94
28
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.
29
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.
30
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
MAINTAIN
EQUIPMENT
31
OPERATE PLANT
32
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.
33
34
OPERATE
PLANT
Inspection Requirements
Work Permit Requests
Notification of Work Completion
MAINTAIN EQUIPMENT
CONSTRUCT & Define Plan Actual Prepare For Maintain
PRE-COMMISSION Maintenance Maintenance
DEMOLISH PLANT
Maintenance Or
PLANT Approach Or Or Inspect & RESTORE SITE
Inspection Inspection Equipment
35
36
MAINTAIN EQUIPMENT
37
2.5 Obtain Plant and Equipment Drawings Obtain authorisation to allow work to be executed and the
Obtain the drawings for the plant and each item of equipment conditions that must be fulfilled to perform the work safely.
in the plant to be maintained. 3.6 Obtain Inspection Report
2.6 Obtain Maintenance Procedures The inspection report records the results of the last inspection
Obtain the procedures which provide information for of an equipment item with details of conditions inspected e.g.
performing tasks relating to routine, preventative, inspection Test Pressure.
and corrective maintenance activities.
2.7 Obtain Plant Availability Requirements 4. Maintain or Inspect Equipment
Obtain the plant availability requirements which the Prepare the site and perform the required maintenance or
maintenance must achieve. inspection.
2.8 Identify Resource Requirements 4.1 Prepare the site for work
Identify the resources in personnel, spares and special tools Perform any preparatory work on the site before undertaking
required to perform the maintenance or inspection. maintenance or inspection.
2.9 Schedule Maintenance & Inspection 4.2 Perform Maintenance or Inspection
Schedule the maintenance or inspection required. Perform the required maintenance or inspection.
4.3 Record Resources Consumed
3. Prepare for Maintenance or Inspection Provide a record of resources in labour and spares consumed
Prepare to carry out the required maintenance or inspection. in performing the maintenance activities.
3.1 Obtain Equipment Records 4.4 Update Equipment Records
Obtain the records for each item of equipment to be Update the records of activities and work completed on the
maintained or inspected. equipment.
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.
Finalize
Regulatory
Approvals
Plant Status
Plant Records
Inspection Requirements
Regulatory Approvals
DEMOLISH PLANT
& RESTORE SITE
39
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.
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DECOMMISSION PLANT
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
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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 2.3 Produce Demolition And Restoration Plan
Identify the current plant and equipment status, the demolition Produce a demolition and restoration plan which identifies all
and restoration requirements and any hazards involved in demolition and restoration activities, their time and resource
implementing demolition. requirements and dependencies.
1.1 Define Demolition Requirements
Identify demolition requirement for the plant. 3. Prepare Plant For Demolition
1.2 Define Restoration Requirements Prepare the plant for demolition.
Identify the restoration requirement for the plant. 3.1 Obtain Equipment Records
1.3 Perform Safety & Environment Study Obtain the records for each item of equipment to be
Perform a safety and environment study to ensure that the demolished.
plant may be demolished in a safe manner without hazard to 3.2 Obtain Plant and Equipment Drawings
personnel or the environment. Obtain the drawings for the plant and each item of equipment
to be demolished.
2. Plan Demolition And Restoration 3.3 Obtain Maintenance Procedures
Identify the current plant status and produce the demolition and Obtained the procedures which provided information for
restoration plans. performing the maintenance or inspection of the equipment
2.1 Produce Demolition Procedures to be demolished.
Identify any hazards involved with the demolition and 3.4 Obtain Resources
restoration activities and define procedures to manage them Obtain the resources in personnel, spares and special tools
in a safe manner. required to perform the demolishment of the equipment.
2.2 Produce Resource Estimates 3.5 Obtain Work Permit
Produce estimates for the resources required for the Obtain an authorisation for work and the conditions
demolition or restoration of the plant. necessary for it to be carried out safely.
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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
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