PROCESS PLANT ENGINEERING ACTIVITY MODEL

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

Copyright Notice
The copyright of the contents of this presentation 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 acknowledgment is
made.

ACKNOWLEDGMENTS
The following organizations provided the information that was used to generate and review the model.
AMEC Engineering Ltd.
AKZO Engineering bv
BP International Ltd.
British Nuclear Fuels plc
Eutech Engineering Solutions Ltd
Harrow Associates
ICI Engineering Ltd.
Ingevision Framatome Systems dInformation

John Brown Engineers & Constructors Ltd.

Lloyd's Register of Shipping
Nuclear Electric plc
Process Industries STEP Consortium (PISTEP)
Shell International
SINTEF
University of Newcastle on Tyne

P Harrow colact1 PISTEP 14-02-02

PROCESS PLANT ENGINEERING ACTIVITY MODEL

Safety & Environment Case

MANAGEMENT ACTIVITIES
SET ENGINEERING
POLICY &
STANDARDS

PRODUCE & MAINTAIN

FEASIBILITY &
FINANCIAL CASE

CONTROL OPERATIONS
& ENGINEERING
ACTIVITIES

OBTAIN
AGREEMENT WITH
REGULATORY BODIES

REGULATORY BODIES
Regulatory Requirements
Authorizations

Process Definition
Control Philosophy
Costs, Benefits & Timings
Safety / Regulatory Requirements

PRODUCE
CONCEPTUAL
PROCESS DESIGN

Performance Requirements
Operating Procedures
Operating Conditions
Alarm / Trip Settings
Safety and Environment Case

PRODUCE DETAILED
PROCESS DESIGN

Process Stream Data

Process Flow Diagrams
Costs, Benefits & Timings

Detailed Process Design

Availability Requirements
Safety Systems Specifications
Operating Procedures
Codes & Standards

Preliminary Engineering Design

Engineering Philosophies
Availability Requirements
Cost & Time Estimates
Safety / Regulatory Requirements
Codes & Standards
PRODUCE CONCEPTUAL
ENGINEERING
DESIGN

Detailed Engineering Design

Equipment Procedures
Vendor Drawings
Spares Lists

Materials & Equipment

Requirements & Specifications
Required on Site Dates

Materials & Equipment

Requirements &
Specifications
Required on Site Dates
Inspection Results
Shipping Details
Payment Details

Equipment Procedures
Delivery Dates
Vendor Drawings
Certification
Equipment & Materials Catalogues
Invoices
SUPPLIERS
&
FABRICATORS

COMMISSION PROCESS
& HANDOVER PLANT

As Built Drawings
Equipment Commissioning Procedures
Equipment Operating Procedures
Inspection & Testing Records
Handover Certification

PRODUCE DETAILED
ENGINEERING
DESIGN

Delivery Dates
Vendor Drawings
Certification
Equipment Procedures
Equipment & Materials
Catalogues

Plant Status
Ground Drains Status
Safety Case
As Built & As Modified Drawings

As Built Drawings
Operating Procedures
Acceptance Test results
Handover Certificate

OPERATE
PLANT

Plant Status
Plant Records
Inspection Requirements
Regulatory Approvals

Engineering Work Requests

Working Conditions Requirements
Engineering Work Permits
Acceptance of Engineering Work

Inspection Requirements
Work Permit Requests
Notification of Work
Completion

As Built Drawings
As Built Equipment Specifications
Spares Lists
Installation Procedures
Maintenance Procedures
Inspection Results
Unfinished Work Details

CONSTRUCT &
PRE-COMMISSION
PLANT

Delivery Dates
Vendor Drawings
Certification
Equipment Procedures
Equipment & Materials Catalogues
Inspection Results
Shipping Details

DECOMMISSION
PLANT

State of Equipment
Value of Equipment
Equipment Records

MAINTAIN
EQUIPMENT

DEMOLISH PLANT &

RESTORE SITE

Materials & Equipment

Requirements & Specifications
Required on Site Dates

Disposal Records
Restoration Records
Handover Records
Final Regulatory Approvals

PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES

P Harrow colact1 PISTEP 14-02-02

PRODUCE CONCEPTUAL PROCESS DESIGN

Define
Overall
Requirement

Identify
Candidate
Processes

Define End
Requirements

Identify Start Conditions

- Define Battery Limits
- Identify state of Plant
to be modified

Design
Process

Provide Input to
Feasibility /
Financial
Case

Identify
Safety / Regulatory
Requirements

PRODUCE
DETAILED PROCESS
DESIGN

Define Unit
Operations
Produce Energy /
Mass Balance
Produce Composition
of Process Streams

Process Definition
- Process Stream Properties
& Composition
- Required Unit Operations
- Process Flow Diagrams
- Energy Balance
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 14-02-02

PRODUCE CONCEPTUAL PROCESS DESIGN

PRODUCE
DETAILED
ENGINEERING
DESIGN

PRODUCE CONCEPTUAL ENGINEERING DESIGN

Determine
Engineering
Approach

Review
Process
Design
Determine
Status of
Existing
Plant
Define
Engineering
Design
Strategy
Obtain Codes &
Standards

Produce Conceptual
Mechanical
Engineering
Design

Produce Conceptual
Electrical
Engineering
Design

Produce Conceptual
Control &
Instrumentation
Engineering Design

Produce Conceptual
Safety
Engineering
Design

Identify
Materials of
Construction

Identify
Materials of
Construction

Identify
Materials of
Construction

Produce Major
Equipment Design
Philosophy

Produce Major
Equipment Design
Philosophy

Produce Major
Equipment Design
Philosophy

Produce
Preliminary
Equipment & Line
Specifications

Produce
Preliminary
Equipment
Specifications

Produce
Preliminary
Equipment
Specifications

Define
Containment
Philosophy

Produce Cost
& Time Estimates

Produce Cost
& Time Estimates

Produce Control
System Architecture

Produce
Technical
Risks Assessment

Produce
Preliminary
Weight &
Volume Estimates

Produce
Preliminary
Weight & Volume
Estimates

Produce Cost
& Time Estimates

Define
Commissioning
Philosophy

Define
Commissioning
Philosophy

Produce Preliminary
Weight & Volume Estimates
Define Commissioning
Philosophy

Define
Preliminary
Plant
Layouts

Define
Safety
Philosophies

Review Site
Alternatives &
Conditions

Identify
Regulatory
Requirements

Produce
Preliminary
Layout
Drawings
Produce
Studies for
Cranage &
Handling

Produce Conceptual
Civil / Structural
Engineering
Design

Produce Site Survey / Soil

Investigation
Define Civil / Structural
Philosophies
Identify Materials of
Construction
Produce Preliminary Building
or Module Layout Drawings
Produce Major Civil /
Structural Specifications
Produce Preliminary
Weight & Volume
Estimates
Produce Cost
& Time estimates
Define Construction
Philosophy

Preliminary Engineering Design

- Equipment Lists
- Preliminary Equipment
Specifications
- Materials of Construction
- Utility Requirements
- Preliminary Layout Drawings
- Weight & Volume Estimates
- Control Systems Architecture
- Technical Risks Assessment
Engineering Philosophies
- Design Philosophy
- Construction Philosophy
- Commissioning Philosophy
- Operations Philosophy
- Safety Philosophies
- Containment Philosophy
Availability Requirements
Cost & Time Estimates
Safety / Regulatory Requirements
Codes & Standards

Define Building / Structural

Commissioning Philosophy

P Harrow colact1 PISTEP 14-02-02

PRODUCE CONCEPTUAL
PROCESS DESIGN
COMMISSION
PROCESS &
COMMISSION
PLANT

PRODUCE DETAILED PROCESS DESIGN

Produce Piping &
Instrumentation
Diagrams

Produce Functional
Specification
for Equipment

PRODUCE
DETAILED
ENGINEERING
DESIGN

Produce Control
Requirements
Specification

Satisfy
Safety
Requirements

Identify
Control
Requirements

Define Relief &

Blowdown Philosophy

Identify
Trip
Requirements

Define Protective
System (Including Fire)
Philosophy

Produce
Control
Requirements
Specification

Define Hazardous Areas

Detailed Process Design

- Piping & Instrumentation Diagrams
- Functional Specifications
- Control Specifications
- Alarm / Trip Settings
- Utility Systems Requirements
- Design Philosophies
Availability Requirements
Safety Systems Specifications
Operating Procedures
Codes & Standards

Produce Plant
Operating
Procedures

Performance Requirements
Operating Procedures
Operating Conditions
Alarm / Trip Settings
Safety and Environment
Case

Produce Safety &

Environment Case

P Harrow colact1 PISTEP 14-02-02

PRODUCE DETAILED
PROCESS DESIGN
PRODUCE DETAILED ENGINEERING DESIGN

PRODUCE
CONCEPTUAL
ENGINEERING
DESIGN

Produce Detailed
Mechanical
Engineering
Design
Produce Piping &
Mechanical
Equipment Design
Produce Equipment
Handling Systems
Design
Produce Detailed
Mechanical
Equipment
Specifications
Define Mechanical
Equipment Spares
Requirements
Produce Mechanical
Maintenance
Procedures

Produce Detailed
Electrical
Engineering
Design

Produce Detailed
Control &
Instrumentation
Engineering Design

Review & Detail

Plant / Building
Electrical
Requirements

Review & Detail

Instrumentation
Plant / Building
Requirements

Produce Earthing
Requirements
(Static,
Lightning, Power)

Produce Clean
Earthing
Requirements

Produce
Communication
System Design
Produce Electrical
Equipment
Specifications
Produce Electrical
Cable Runs Design
Produce Power
Distribution
Systems
Design
Produce Electrical
Environment
Control
Requirements
Define Electrical
Equipment Spares
Requirements
Produce Electrical
Maintenance
Procedures

Produce Detailed
Layout &
Construction
Design

Produce
Measurement
Instrumentation
Specification
Produce Actuator
Specifications
Produce Control
Systems
Specifications
Define Signal
Transmission
Pathways

Produce Site
Layout
Produce 3D
Plant Model
Coordinate
Interfaces
Between Design
Areas
Produce Site
Construction &
Installation
Methodology
Define Test &
Pre-Commissioning
Requirements

Produce Building
& Plant
Services Design
Produce
Domestic
Water,
Sewage &
Storm Water
Design
Produce
Environmental
Control
Systems
Design
Produce
Lighting &
Small Power
Design
Produce Fire
Protection
Systems
Design

Produce Environmental
Control Requirements
for Instrumentation
Define Instrumentation
& Control Equipment
Spares Requirements

Produce Detailed
Civil / Structural
Engineering
Design

Produce Detailed
Safety
Engineering
Assessment

Produce Site Survey /

Soil Investigation

CONSTRUCT &
PRE-COMMISSION
PLANT

Produce Room / Module

Specifications
Produce Civil
Construction
Drawings
Design Containment
Systems
Design Process
Effluent Drainage
Systems
Design Foundation
Structures
Produce Painting &
Surface Finish
Specifications
Produce Weight
Schedules
Produce Bill Of
Quantities

Detailed Engineering Design

- Detailed Equipment Specification
- Piping & Instrumentation Diagrams
- 2D Schematics
- 3D Model
- Construction Drawings
Equipment Procedures
- Installation Procedures
- Commissioning Procedures
- Operating Procedures
- Maintenance Procedures
Vendor Drawings
Spares Lists

Produce Instrumentation
& Control Maintenance
Procedures

Equipment & Materials Requirements

and Specifications
Required on Site Dates

PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES

P Harrow colact1 PISTEP 14-02-02

Equipment & Materials Catalogues

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

Equipment & Materials Catalogues

- Equipment & Materials Specifications
- Equipment & Material Availability & Prices
- Spares Lists
Delivery Dates
Vendor Drawings
Certification
Equipment Procedures
- Installation Procedures
- Commissioning Procedures
- Operating Procedures
- Maintenance Procedures

Equipment & Materials Catalogues

- Equipment & Materials Specifications
- Equipment Availability & Prices
- Spares Lists
Delivery Dates
Vendor Drawings
Certification
Equipment Procedures
- Installation Procedures
- Commissioning Procedures
- Operating Procedures
- Maintenance Procedures
Invoices

SUPPLIERS &
FABRICATORS

Equipment & Materials Requirements &

Specifications
Required on Site Dates
Inspection Results
Shipping Details
Payment Details

PRODUCE
DETAILED
ENGINEERING
DESIGN

CONSTRUCT &
PRE-COMMISSION
PLANT

MAINTAIN
EQUIPMENT

PROCURE & CONTROL EQUIPMENT MATERIALS & SERVICES

Maintain
Suppliers
List

Issue
Enquiries

Evaluate
Bids

Commit
Purchase

Expedite
Manufacture

Maintain List
Of Preferred
Suppliers

Compile
Bidders
List

Condition
Bids

Produce
Purchase
Orders

Expedite
Progress

Maintain
Relationship
with Suppliers

Produce
Enquiry
Documents
Compile
Conditions
of Contract

Select
Supplier

Confirm
Final
Conditions
of Contract

Authorize
Stage
Payments
Respond to
Technical
Queries

Inspect

Inspect
Equipment,
Materials
& Services
Respond to
Concession
Requests

Release for
Shipment
From Supplier

Ship Goods
From
Supplier

Control
& Issue
Equipment
& Materials

Issue
Release Note

Pack
Goods

Produce Material
Stock Strategy

Close out
Purchase
Order

Make
Shipping
Arrangements

Unload
Goods

Authorize
Final
Payments

Ship Goods

Store Goods
Control &
Monitor
Stock
Issue & Transport
Goods To Required
Location

P Harrow colact1 PISTEP 14-02-02

COMMISSION PROCESS
& HANDOVER PLANT
As Built Drawings
Equipment Commissioning Procedures
Equipment Operating Procedures
Inspection & Testing Records
Handover Certification

PRODUCE
DETAILED
ENGINEERING
DESIGN

MAINTAIN
EQUIPMENT

CONSTRUCT & PRE-COMMISSION PLANT

Produce
Construction
Plans
Produce
Contract
Plan
Produce
Construction
Plan

Establish
Construction
Services

Erect
Plant

Produce
As-Built
Surveys

Pre-Commission

Perform
Civil /
Structural
Construction

Perform
Conformance
Checks

Clean Plant for

Testing and
Commissioning

Erect Major
Plant Items

Produce
As-Built
Specifications
& Drawings

Prepare Equipment
for Commissioning

Construct
Piping
Install Electrical
& Instrumentation
Systems

Identify
Unfinished
Work

Perform
Pre-commissioning
Tests
Perform Baseline
Inspection

Handover
To Process
Commissioning

As Built Drawings
As Built Equipment Specifications
Spares Lists
Installation Procedures
Maintenance Procedures
Inspection Results
Unfinished Work Details

Complete Special
Finishes, Thermal
Insulation & Painting

PROCURE & CONTROL

EQUIPMENT, MATERIALS
& SERVICES

P Harrow colact1 PISTEP 14-02-02

PRODUCE
DETAILED
PROCESS
DESIGN

OPERATE
PLANT

COMMISSION PROCESS & HANDOVER PLANT

Produce
Commissioning
Plan

Train
Commissioning
Personnel

Commission
Plant

Perform Trip
Tests
Perform Cold
Commissioning
Perform Hot
Commissioning
Tune Control
Systems

Perform
Acceptance
Testing

Identify Plant
Performance
Envelope
Compare
Performance to
Specification
Identify Corrective
Actions &
Responsibility

Handover
Plant For
Operation

Update Operating
Procedures
Finalize
Agreement
With Regulatory
Bodies

As Built Drawings
Operating Procedures
Acceptance Test results
Handover Certificate

Perform Plant
Handover

CONSTRUCT &
PRE-COMMISSION
PLANT
P Harrow colact1 PISTEP 14-02-02

COMMISSION PROCESS
& HANDOVER PLANT

OPERATE PLANT

DECOMMISSION
PLANT

Ensure
Safe Plant
Operation

Plan &
Schedule
Plant
Operation

Obtain Operating
Procedures

Define
Operating Modes

Operation
Of Plant

Configure Plant
Start-up Plant

Obtain Operating
Schematics

Plan Plant
Operations

Define Safety
And Security
Procedures

Schedule Plant
Operations

Monitor Plant
Performance
Optimize Plant
Performance

Obtain Certificate
to Operate

Account for Plant

Performance

Maintain Safety
Case

Shutdown &
Clean Out Plant

Train Operating
Personnel

Dispose of
Inventory

Request and
Approve Work
on Plant

Identify
Requirement
for Engineering
Work

Plant Status
Ground Drains Status
Safety Case
As Built & As Modified Drawings

Request
Engineering Work
Approve Work
Permits
Ensure Safe
Working
Conditions
Accept
Engineering
Work

Engineering Work Requests

Working Conditions Requirements
Engineering Work Permits
Acceptance of Engineering Work

MAINTAIN
EQUIPMENT
P Harrow colact1 PISTEP 14-02-02

OPERATE
PLANT
Inspection Requirements
Work Permit Requests
Notification of Work Completion

MAINTAIN EQUIPMENT
CONSTRUCT &
PRE-COMMISSION
PLANT

Define
Maintenance
Approach

Prepare For
Maintenance
Or
Inspection

Plan Actual
Maintenance
Or
Inspection

Maintain
Or
Inspect
Equipment

Obtain Plant Availability

Requirements

Respond to Maintenance
Request

Obtain Equipment
Records

Prepare Site
for Work

Obtain Equipment
Records

Identify Routine
Maintenance Requirement

Obtain Plant &

Equipment Drawings

Obtain Plant &

Equipment Drawings

Perform
Maintenance
or Inspection

Identify Inspection
Requirements

Obtain Maintenance
Procedures

Obtain & Develop

Maintenance
Procedures

Obtain Equipment Records

Obtain Resources

Obtain Plant & Equipment

Drawings

Obtain Work Permits

Define Preventative,
Breakdown, Shutdown
Maintenance Strategy

Obtain Inspection
Reports

Obtain Maintenance
Procedures

Obtain & Develop Spares

Strategy

Obtain Plant Availiability

Requirements

Obtain Hazardous
Materials Data

Identify Resource
Requirements

Train Maintenance &

Inspection Staff

Schedule Maintenance
& Inspection

DEMOLISH PLANT
& RESTORE SITE

State of Equipment
Value of Equipment
Equipment Records

Record
Resources
Consumed
Update
Equipment
Records

Materials & Equipment Requirements & Specifications

Required on Site Dates

PROCURE & CONTROL

EQUIPMENT, MATERIALS
& SERVICES
P Harrow colact1 PISTEP 14-02-02

DECOMMISSION PLANT
OPERATE
PLANT

Define
Decommissioning
Requirements

Identify Current
Status
Define Final
Status

Produce
Decommissioning
& Restoration
Plan

Perform
Preparatory
Works

Clean &
Mothball
Plant

Isolate Services

Clean Plant

Provide
Temporary Services

Mothball Plant

Provide
Decommissioning
Equipment

Archive Plant
Records
Determine
Inspection
Requirements
Finalize
Regulatory
Approvals

Plant Status
Plant Records
Inspection Requirements
Regulatory Approvals

DEMOLISH PLANT
& RESTORE SITE

P Harrow colact1 PISTEP 14-02-02

DECOMMISSION PLANT

DEMOLISH PLANT AND RESTORE SITE

MAINTAIN
EQUIPMENT

Define
Demolition &
Restoration
Requirement

Plan
Demolition
& Restoration

Define
Demolition
Requirements

Produce
Demolition
Procedures

Define
Restoration
Requirements

Produce Resource
Estimates

Perform Safety &

Environment Study

Produce
Demolition &
Restoration
Plan

Prepare
for Plant
Demolition

Obtain Equipment
Records
Obtain Plant &
Equipment Drawings
Obtain Maintenance
Procedures
Obtain Resources

Demolish &
Secure Plant

Prepare Site
Remove
Plant
Dispose of
Plant
Box up &
Secure Plant
To Remain

Obtain Work Permits

Restore
Site

Survey Site
Contamination
Remove / Treat
Contaminated
Material

Dispose of
Site

Archive Records
Finalize
Regulatory
Approval

Dispose of
Contaminated
Material
Restore
Environment

Obtain Inspection
Reports

Disposal Records
Restoration Records
Handover Records
Final Regulatory Approvals

P Harrow colact1 PISTEP 14-02-02