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2013

Engineering Design QA
Holistic Workflow Philosophy
Renatus Engineering best practice guidance to engineering managers for the delivery of technical
integrity

Renatus Engineering
1/1/2013

TABLE OF CONTENTS
Engineering Design Integrity Workow (EDIW): .................................................................................................................................................................................................... 2
Phase 1 Scope Denition and Engineering Execution Strategy - PROPOSAL ................................................................................................................................................ 3
Phase 2 Commencement of Detail Design SITE VISIT ......................................................................................................................................................................................... 5
Phase 3 Initial Design Development and Hazard Identication 10% ........................................................................................................................................................... 6
Phase 4 Initial Design Review and Audit 35% ........................................................................................................................................................................................................ 7
Phase 5 Design Approval 35% RETURN ................................................................................................................................................................................................................... 8
Phase 6 Approval for Construction - 90%.................................................................................................................................................................................................................... 9
Phase 7 Design Close-Out..................................................................................................................................................................................................................................................10

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ENGINEERING DESIGN HOLISTIC WORKOW (EDHW):


The best practice guidance to engineering managers for the delivery of technical integrity. This document highlights the key deliverables and
activities throughout the lifecycle of a typical detailed design project.
1.
2.
3.
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8.

Detailed Design Is Broken Into Seven Phases:


Scope Denition and Engineering Execution Strategy
Commencement of Detailed Design
Initial Design Development and Hazard Identication
Initial Design Review & Audit
Approval for Design
Approval for Construction
Design Close-Out

The workow shown above illustrates the execution sequence of a generic Detail Design Project. Some work can be undertaken concurrently
however a sequential ow of work is the standard. As the deliverables and activities in each phase are completed, work can transition into the
next phase.
Situations will arise when work will need to be done out of sequence, typically to meet a demanding project schedule. Use of this process allows
the risks of out-of-sequence working to be identied and the necessary mitigation strategies to be put in place.
Renatus Engineering Quality Control Manager (QCM) will measure compliance with the workow and ensure out-of-phase working is being
identied and managed. This document contains a copy of the Detail Design EDHW Workow Road Map and includes detailed descriptions of the
activities, the key engineering disciplines and supporting documentation.

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PHASE 1 SCOPE DEFINITION AND ENGINEERING EXECUTION STRATEGY - PROPOSAL


Preparation for commencement of detail design. To evaluate deliverables to ensure engineering is sufciently mature for detail design to
progress in a controlled and minimal change environment.
ACTIVITIES/DELIVERABLE

DESCRIPTION

DISCIPLINE
Project Manager
and Project
Engineering
Manager
Project
Engineering
Manager

Proposal documentation and Project


Execution Plan (PEP)

Project
Engineering
Manager

Engineering Baseline Standards,


unified facilities guidance (UFG), other
design guides. (ie VA guidelines)

Project
Engineering
Manager

Technical Safety Events Schedule


(Lead Technical Safety Engineer), MS
project template should be developed.

Level 1 - Engineering
Execution Strategy
Proposal Documentation

Review / conrm Engineering Execution Strategy ,


e.g. execution locations, workshare, disciplines
required, specialist support, etc.

FEED / AS BUILD
Validation

Project Baseline
Standards

Engineering Audit
Schedule

Level 2 - Engineering
Execution Plan &
Engineering
Organization Chart
Integrated Engineering
Systems

Conrm maturity of Preliminary Engineering


Documents (PED) 10% deliverable also known as
the front end engineering design (FEED). Identify
any areas of concern and ensure these are
captured on the Technical Risk Register.
Establish which codes, standards and
specications are to be utilized, ie. Corporate,
project, client, and conrm procedure. Include in
Engineering Execution Plan and / or Discipline Job
Design Specications.
Create formal schedule to identify when technical
integrity audits (rule of thumbs or best have
discipline specialist review), design reviews
(coordination review), hazard identifications,
hazards operation, etc are to be carried out. Align
to Level 3 Engineering Plan and include in
Engineering Execution Plan.
Create Engineering Execution Plan complete with
key supporting documents / information.
Supporting documents are those generated above

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Agree when its a team and determine when its a


single individual what engineering design tools to
be used and conrm that system hardware,
software and support is available. The customer

SUPPORTING DOCUMENTATION

Project
Engineering
Manager
Engineering
Systems and All
Disciplines

Fins or develop an Engineering


Systems Project Start-up Manual,
Document No. OAGX160-170-MAN002

Quantitative Risk
Assessment Strategy

Discipline Job Design


Specication

Level 3 Engineering Plan

10

Technical Risk Register

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will drive much but the general guidelines will be,


specintact, RSMeans, and Revit everything else
becomes an issues such as easypower, PDMS or
PDS, Catalog cuts for basis of design and Other
Specs, survey methods, drawings dimensional
control techniques, etc. Document and record in
the Engineering Execution Plan and discipline job
design specications.
Establish status of project Quantitative Risk
Assessment and conrm methodology for timely
delivery into engineering design process. Agree on
accountability for delivery, ie. Client, 3rd party,
Renatus, and record in Engineering Execution Plan.
Dene the key project specic design parameters
and operational constraints that are applicable to
the appropriate discipline for the detailed design of
the project (wall, plumbing, fire protection). To
identify key individuals, roles and responsibilities,
design tools, key codes and standards, etc.
Specintact guide specifications will tell you all this
Agree on work breakdown structure (uniformat ii
or masterformat), and create level 3 integrated
engineering plan covering all disciplines. To be
included in Engineering Execution Plan.
Create formal Technical Risk Register identifying
all possible risks associated with the engineering
design.

Technical Safety

All Disciplines

All Disciplines

Technical Safety

Develop or find manual on Hazard &


Risk Management.

PHASE 2 COMMENCEMENT OF DETAIL DESIGN SITE VISIT


To formally kick off the Engineering Design Process in accordance with the project execution plan and to ensure that key engineering strategies /
philosophies are in place.
ACTIVITIES/DELIVERABLE
1

Performance Standards &


Verication Scheme

Document Distribution
Matrix

Structural Integrity
Interface

Material Selection Report

Hazard Management Plan

Discipline Specications

PDMS Catalogues

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DESCRIPTION
Conrm safety critical systems / elements and set
appropriate performance standards. ie.
functionality, reliability and survivability. Develop
scheme to allow an independent competent body
to verify the design against the performance
standards.
Create formal document distribution matrix to
ensure all disciplines & departments receive all
necessary design information in a timely manner.
Ensure structural integrity interfaces are
identied & visible to Project, ie Renatus / Client
focal points, Technical Authorities, Independent
Verication Bodies, etc.
Report dening the requirements and
specications of necessary material.
Create Hazard Management Plan identifying all
key hazards (confined space, hazardous materials,
electrical hazards, fall hazards, etc) technical
safety activities and the approach to managing
Major Accident Hazards in the design.
Develop / conrm baseline specications,
utilizing specintact specications where possible.
Ensure PDMS catalogues are populated &
available for all affected disciplines, utilizing
online search (making sure to convert data to
generic standards), where possible.

DISCIPLINE
Technical Safety

SUPPORTING DOCUMENTATION
Develop and find Hazard Management
Philosophy, Hazard & Risk
Management,; Design Verication
Activities ; Platform Safety Case.

Project
Engineering
Manager
Structural

Discipline

Material Engineering Selection.

Technical Safety

Develop of find: Hazard & Risk


Management,; Management of
Functional Safety Guideline

ALL.
ALL

PHASE 3 INITIAL DESIGN DEVELOPMENT AND HAZARD IDENTICATION 10%


To develop initial design deliverables to Inter Discipline Review stage and identify key hazards.
ACTIVITIES/DELIVERABLE
1

Hazard Identification

Environmental Issue
(NEPA)

3
4

System and Process


Diagram
Plot Plans / Layouts

Equipment List

Mechanical Handling
Strategy

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DESCRIPTION
Perform hazard identication studies, as
identied on Engineering Audit Schedule /
Technical Safety Events Schedule.
Formal assessment of environmental aspects
associated with a modication or a change, and to
propose prevention or mitigating measures.
Issue System and Process Flow / control
Diagrams on formal Inter-Discipline Review.
Issue equipment Plot Plans / Layouts on formal
inter-Discipline Review.
Create master project equipment list identifying
all major items of tagged equipment, ie. vessels,
pumps, motors, generators, chemical injection
packages, electrical switchgear, control panels,
etc.
Develop Mechanical Handling Strategy including
general approach / constraints, platform crane
limits, installation philosophy, operation and
maintenance, etc.

DISCIPLINE

SUPPORTING DOCUMENTATION

Technical Safety

Technical Safety

Mechanical and
Electrical

Mechanical and
Electrical

Mechanical and
Structural

Develop or Reference: Environmental


Impact Identication Engineering &
Design Reviews manual

PHASE 4 INITIAL DESIGN REVIEW AND AUDIT 35%


To conrm that the initial design development is strong.
ACTIVITIES/DELIVERABLE
1

Hazardous Area Review

Special design
consideration Review

Plot Plans / Layout / 3-D


Model Review

4
5

LEED Review
Technical Audit

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DESCRIPTION
Formal Engineering discipline review of
hazardous area layouts to conrm requirements
for the correct selection and location of
equipment.
Formal Engineering unique process or system to
conrm design basis.
Formal Engineering review of Plot Plans /
Layouts. The review shall ensure that the layout
design complies with the required technical,
safety, operability and maintainability standards.
Makes sure the layout is cost effective, ensures the
constructability of the work and agrees the layout
basis on which the detailed design can proceed.
Formal review of ?????????????
Obtain conrmation, by sampling of project
documentation, that the engineering of the project
is to the required standard and free from errors.

DISCIPLINE

SUPPORTING DOCUMENTATION

Technical Safety

Hazard and Risk Management


Procedure; Engineering & Design
reviews,

Process, Piping,
Technical Safety,
Instruments
Structural,
Mechanical,
Electrical,

Engineering & Design Reviews,

Independent
(Renatus QA
Engineering)

Technical Audit Procedure

Engineering & Design Reviews,

PHASE 5 DESIGN APPROVAL 35% RETURN


To Freeze the process design, and develop dependent design & procurement activities.
ACTIVITIES/DELIVERABLE
2

Operability

OSHA & NEPA Audit

Environmental Report

Constructability Review

10
15

Holds Register
Process Assurance

16

Verication of Vendor
Information &
Certication - Design
Completion

17

Compliance Report

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DESCRIPTION
Operability Studies, a systematic multi-discipline
study based on the applications of guidewords to
identify causes of potential failure and operability
constraints in a facility.
Audit to ensure that the design falls under The
Health and Safety At Work Act 1974 and project
health, safety and environmental performance
standards are being or have been met during the
engineering and design processes.
Issue nal report to document & conrm that the
design has considered all applicable
environmental aspects & demonstrates that
design controls have been included to minimize /
control the environmental impact.
Conduct formal Constructability Reviews to
ensure safe and efcient installation of equip.
Develop register to record & manage design holds.
Conduct process studies to demonstrate the
process design under a range of conditions, ie
equipment start-up, etc.
Verify, primarily through review of vendor
documentation, that their design & manufacture
of fabricated packages, etc is robust and contains
sufcient information to facilitate completion of
affected Renatus discipline design.
Issue nal report as documented conrmation
that the design meets the requirements of the
10% review

DISCIPLINE

SUPPORTING DOCUMENTATION

Process,
Technical Safety

Technical Safety

Find links

Technical Safety

(COTR/CM)
Engr Manager
Process

Affected
disciplines

Technical Safety

Engineering & Design Reviews,

PHASE 6 APPROVAL FOR CONSTRUCTION - 90%


To ensure that sufcient design information & certication is available to facilitate safe installation, operation & maintenance.
ACTIVITIES/DELIVERABLES

D E S C R I P TI O N

Customer Compliance
Report
Cost Report

Final report to formally demonstrate that the


system comply with the requirements.
Cost estimate.

Construction Specification

Approved For Construction report.

Construction Drawings

Approved For Construction report.

10

Verication of Vendor
Information &
Certication - Installation,
Operation & Maintenance

11

Design Certi cates

Verify, primarily through review of vendor


documentation, that their design & manufacture
of fabricated packages, etc is robust and contains
sufcient information to facilitate safe installation,
operation & maintenance.
Applicable consultant provide seals

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KEY DISCIPLINE

Instruments
Affected
Disciplines
Affected
Disciplines
Affected
Disciplines
Affected
Disciplines

SUPPORTING DOCUMENTATION

PHASE 7 DESIGN CLOSE-OUT


To ensure all nal design deliverables are completed and that client and statutory obligations are satisfactorily resolved.
ACTIVITIES/DELIVERABLES

D E S C R I P TI O N

Transmittal letter

Submit deliverable to customer.

Certifying Authority (CA)


/ Independent
Verication Bodies (IVB)
Acceptance
Complete Project AsBuilt Documentation

Close out all outstanding technical queries and


obtain nal Letter of Acceptance.

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Complete as-builts of design drawings and


deliverables in accordance with Project / Client
requirements.

KEY DISCIPLINE

Affected
Disciplines
Affected
Disciplines

Affected
Disciplines

SUPPORTING DOCUMENTATION