Front-End Loading

Downstream Project Checklist

CONFIDENTIAL
This document is the proprietary property of Independent Project Analysis, Inc., which retains all copyright and other ownership rights in its
contents. Information about the subject matter, content and structure of this document is confidential and proprietary. Neither this document nor
any such information may be disclosed to any third party without the prior written consent of IPA except as expressly provided by the contract
between IPA and the client to whom IPA has delivered this document.

FEL WORKSHOP – CONFIDENTIAL IPA, Inc.

FEL Checklist: Project Objectives and Priorities
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Project objectives clearly defined

Operating capacity derived from nameplate (instantaneous rate) and the
operating factor

Project completion dates defined

Sequence of mechanical T/O

Production ramp-up rates

Project "philosophy" defined

Expandability

Flexibility

Reliability
Risks & uncertainties that can influence success of this project
identified.

What constitutes success of this project is clearly defined.

Safety & health standards defined in compliance with corporate policies.

Occupational health criteria included in basic data

Safety & fire codes reviews completed

Hazops reviews done at appropriate times

Environmental permitting/regulatory plan developed for all project

activities required to obtain permits and insure regulatory compliance
All permit requests submitted

Impact of this project on existing waste treatment facilities

defined

FEL WORKSHOP – CONFIDENTIAL 1 IPA, Inc.

FEL Checklist: Project Objectives and Priorities (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Value-improving practices defined

Technology selection
Waste minimization

Customizing standards and specifications

Classes of facility quality
Process simplification

Process reliability modeling

Prediction maintenance
Design-to-capacity
Value Engineering

Energy optimization

Constructability reviews

3-D CAD
Incorporate "lessons learned" from historical experience with similar projects

Contracting strategy defined

Consistent with project objectives and priorities

Definition of bid packages defined in conjunction with turnover
sequence and construction strategy
Procurement strategy defined

Construction strategy defined

FEL WORKSHOP – CONFIDENTIAL 2 IPA, Inc.

FEL Checklist: Project Objectives and Priorities (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Plan to protect proprietary information defined

All land agreements finalized
Joint venture agreements finalized

Project management procedures defined

Criteria defined for making changes
Change control system in place

Criteria defined for making trade-off decisions

Costs
Schedule
Operability

Project control system defined: costs/schedule

Project quality management program defined; e.g., quality of design

documents

Training procedures defined

FEL WORKSHOP – CONFIDENTIAL 3 IPA, Inc.

FEL Checklist: Basic Design Data
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Process steps described

All chemical reactions
Block flow diagrams

Process development uncertainties addressed

Process chemistry
Equipment design

Feedstock composition

Process impurities
Temperature extremes
Pressure extremes

Corrosive material

Abrasive material

Mechanical problems
Corrosion testing to determine adequacy of materials of construction conducted

Potential for build-up of impurities in recycle streams determined

Catalyst effectiveness vs. expected life confirmed

FEL WORKSHOP – CONFIDENTIAL 4 IPA, Inc.

FEL Checklist: Basic Design Data (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility
Potential problems arising from handling solids, slurries, and non-newtonian
liquids resolved
Solids preparation equipment (e.g., grinders)
Solids feeding and injection equipment (e.g., screw conveyors)
Reactors (solid phase material)
Solids transport equipment (e.g., slurry pumps)
Solid/liquid separation equipment (e.g., filters)
Particulate removal equipment (e.g., cyclones)
Need for piloting facilities decided
Integrated pilot plant
Unit demonstration facilities
Vendor equipment
Specifications & purity requirements defined for all products
Physical and chemical properties of raw materials, intermediates, and finished
products have been identified over the full range of operating conditions
Hazards of all materials determined
Flammability
Reactivity
Thermal stability/impact sensitivity
Toxicology determined for all materials
Industrial health needs
Control measures
Applicable requirements and monitoring requirements
Dust explosion potential

FEL WORKSHOP – CONFIDENTIAL 5 IPA, Inc.

FEL Checklist: Site Definition and Plot Plans
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility
Site survey complete
Dismantlement and razing requirements defined
Existing underground installations identified and located
Sewers, water, electrical, utilities, etc.
Previous usage: piping, drums, storage tanks, foundations, etc.
Site remediation needs defined
Soil and groundwater contamination
Dismantlement and decontamination requirements
Decontamination plan approved by business
Geo-technical information defined
Soil borings
Seismic data
Soil percolation
Soil conductivity
Ground water flow rates
Water table

FEL WORKSHOP – CONFIDENTIAL 6 IPA, Inc.

FEL Checklist: Site Definition and Plot Plans (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility
Approved plot plans showing overall plant lay-out
Building arrangements
Equipment arrangements
Pipe bridge locations
Geodetic elevations
Roadways and sidewalks
Fire hydrants
Trenches, sumps, slopes
Underground piping
Temporary construction requirements
Facilities layout reviewed

Constructability

Operability

Maintainability
Fire prevention/safety
Electrical area classifications defined

Underground piping defined and drawings issued for review

Underground electrical defined and drawings issued for review (duct, conduit,
manholes, etc.)

FEL WORKSHOP – CONFIDENTIAL 7 IPA, Inc.

FEL Checklist: Site Definition and Plot Plans (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Storage and tank farm facilities defined

Raw materials
Inventory requirements

Shipment sizes and schedules

Container type, capacity and size
Pallet size and requirements

Spill handling processes and physical requirements

By-products
Inventory requirements
Shipment sizes and schedules

Container type, capacity and size

Pallet size and requirements

Spill handling processes and physical requirements

Products

Inventory requirements

Shipment sizes and schedules

Container type, capacity and size

Pallet size and requirements

Spill handling processes and physical requirements
Compressed gases storage and transfer requirements

FEL WORKSHOP – CONFIDENTIAL 8 IPA, Inc.

FEL Checklist: Site Definition and Plot Plans (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

General safety requirements defined

Mobile and fixed fire fighting equipment
Alarms

Sprinklers
Gas masks
Stretchers

Safety showers

Telephone and autocall systems

Emergency lighting
Fire protection

Employee protective equipment

Support facility requirements defined

OSBL -- size and location

Administration offices

Lunch room

Medical facilities
Laboratories

Locker rooms
Maintenance shops
Yard maintenance

FEL WORKSHOP – CONFIDENTIAL 9 IPA, Inc.

FEL Checklist: Site Definition and Plot Plans (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

General storage
Interconnecting pipe routings
Salvage yard facilities

Shipping
Warehousing
Gate house

Marine facilities

Temporary construction facilities

Laydown yard
Temporary warehousing

Utility requirements

Rail spurs

Marine facilities
General site requirements defined

Fences

Roads and walkways

Parking areas

Other paving
Railroads
Ditches and drainage

Crane access defined -- construction/maintenance phases

Expansion area identified

FEL WORKSHOP – CONFIDENTIAL 10 IPA, Inc.

FEL Checklist: Process Flow Diagrams
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Design volume and composition of all process streams defined

Product

By-product
Waste
All process stream design flow rates frozen

Raw material volume and purity requirements defined

Required off-site facilities identified and shown on PFDs
PFDs reviewed by Operations for normal and abnormal operating conditions
(S/U, S/D, upset, etc.)

PFDs approved by Operations

Flow sheet basis defined

Annual capacity

Operating hours
All process streams defined

Flowrates (weight, volumetric, min/max)

Operating conditions (T & P)

Chemical composition

Heat and material balances finalized

Basis: calculation, pilot plant, plant data
All tie-ins to existing operations defined

FEL WORKSHOP – CONFIDENTIAL 11 IPA, Inc.

FEL Checklist: Process Flow Diagrams (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

All flowsheet equipment defined

Objective of equipment
Description

Basis for selection

Thermodynamics (show calculations)
Reaction kinetics (show calculations)

Phase equilibria (show calculations)

Energy loads (show calculations)

Heat transfer rates and coefficients
Mass transfer rates and coefficients

Material of construction (show test results)

Risks and uncertainties of equipment

FEL WORKSHOP – CONFIDENTIAL 12 IPA, Inc.

FEL Checklist: Process Flow Diagrams (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Utility flow diagrams and balances issued

Steam (source, load, temperature/press)

Cooling water (source, load, temperature/press)

Process water
Refrigeration

Compressed air

Inert gas
Natural gas
Electrical

Utility flow OSBL

Required off-site facilities identified and shown on flow diagrams

Sources of all utility suppliers determined

All tie-ins to existing operations defined

All utility flow diagrams reviewed and approved by Operations

FEL WORKSHOP – CONFIDENTIAL 13 IPA, Inc.

FEL Checklist: Piping and Instrumentation Diagrams -- P&IDs
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

All line data complete

Line size
Jacketing/tracing defined
Piping/valve specifications defined

Pipe code breaks shown

Pipe paint specifications shown

Pipe insulation shown

Relief valves sized and shown

Equipment nozzles sized and identified

Maintenance and/or specification flanges shown
Instrument information complete

Loop functionality

Control valve actions

Instrument power requirements

Instrument freeze protection

Analyzer services

Solenoid valve/air switch porting

Position switch designations
DCS information shown

FEL WORKSHOP – CONFIDENTIAL 14 IPA, Inc.

FEL Checklist: Piping and Instrumentation Diagrams -- P&IDs (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Start-up, shut down, off-test, clean-up and instrument test connections shown
All required tie-ins to existing lines/equipment shown
P&IDs compared with approved flow diagrams

P&IDs of design release quality -- approved by all who can influence project
outcome

HAZOP review completed using approved P&IDs

FEL WORKSHOP – CONFIDENTIAL 15 IPA, Inc.

FEL Checklist: Electrical Single Line Diagrams
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Electric single line diagrams complete

Motor horsepower

Starter size and type

System voltage and phase
Fuse sizing, breaker frame sizing, trip setting references

Motor heater sizing

Proper interrupting ratings

Feeder identifications noted
Substation sizing shown

Feeder cable sizing shown

Circuit between utility incoming transmission

Line and the power substation shown

Electrical classification plot plan approved and issued

Availability of existing utilities confirmed

Utility tie-ins reviewed with local utility

Single line diagrams approved by Operations

FEL WORKSHOP – CONFIDENTIAL 16 IPA, Inc.

FEL Checklist: Process Control Strategy
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Control system summary outlining control philosophy and key components of

the project's control systems approved through Operations

Approved through Operations and Maintenance:

Primary controls system (e.g., DCS, PLC, Etc.)

Other major control elements identified

Shutdown system hardware
Process analyzers

Ambient air analyzers, etc.

Major machinery instrumentation/control philosophy established

Control system equipment layout drawings
Preliminary logic diagrams for key shutdown/interlock systems developed

Tie-ins/interfaces to existing facility control systems identified

Operating procedures completed

Start-up procedures completed

FEL WORKSHOP – CONFIDENTIAL 17 IPA, Inc.

FEL Checklist: Equipment, Piping, and Bulk Materials
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Equipment lists complete and issued (including service equipment)

ISBL
OSBL

Equipment specifications complete

Overall dimensions
Weights (empty, with water, test weight)

Design temperature and pressure

Materials of construction
corrosion allowance
Internals - installation/removal

Special flanges - "match-up"

Equipment nozzle sizes

Support orientation, bolt hole location

Flange finish

Testing procedures

Dimensions/elevations that match tie-in equipment

Grounding lugs and lightning arrestors
Weigh cell supports

Vessel installation procedure

Painting and insulation specification

Welding specifications and process

FEL WORKSHOP – CONFIDENTIAL 18 IPA, Inc.

FEL Checklist: Equipment, Piping, and Bulk Materials (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Equipment data sheets reviewed and approved by Operations and Maintenance

Equipment specifications reviewed for standardization opportunities (pumps,
couplings, seals, etc.)

Validate equipment specifications for transition states; e.g., start-up, shutdown,

and equipment testing

Equipment/arrangement details defined

Supports

Location

Dimensioning and geodetic elevation

Special floor finishes, trenches, sumps
Curbs and containment

Access and egress requirements

Shim allowances and thickness

Equipment laydown space

Equipment removal/maintenance requirements (tube bundles, etc.)

Operating platforms, ladders, etc.

FEL WORKSHOP – CONFIDENTIAL 19 IPA, Inc.

FEL Checklist: Equipment, Piping, and Bulk Materials (cont.)
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility
Other general equipment maintenance requirements
Special tools, bundle pullers, cradles, etc.
Jib cranes and monorails
Welding receptacles
Hoists and lifts
Lock-out points
Work platforms
Provisions for predictive maintenance
Vibration, temperature, flow rates, amperage, etc.
Modifications to existing equipment defined
Spare parts requirements identified
Identify long lead time equipment and material items and develop a plan to
procure them in a timely manner
Project equipment and material plan defined:
Engineered equipment
Procurement
Expediting
Inspection
Traffic
Quality management
Bulks -- Same elements
Develop procurement plans for major equipment, pipe spools, structural steel,
and major bulk materials

FEL WORKSHOP – CONFIDENTIAL 20 IPA, Inc.

FEL Checklist: Schedule
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Milestone schedule showing timing for major tasks completed by the end of the
"select" phase

Network plan and schedule, fully integrating engineering, procurement,

construction, turnover activities and start-up complete by the end of the "design"
phase

Critical path analysis complete

Plan and schedule compared to historical experience with similar projects

Based on the network plan and schedule identify the resources needed to
execute the project

Start-up plan complete

Turnover strategy and sequence complete and integrated with engineering and
construction plans and schedules

Tie-ins and shutdowns involving existing facilities coordinated with Operations

and Maintenance

FEL WORKSHOP – CONFIDENTIAL 21 IPA, Inc.

FEL Checklist: Estimate
OBJECTIVE: Applies? Respon- Schedule Status Comments
(Y/N) sibility

Factored estimate ("C" grade ± 30%), including approximate FEL costs,

completed by the end of the "select" phase

Control estimate ("A" grade ± 10%), based on an integrated network plan and
schedule, completed by the end of the "design" phase

Control estimate compared to historical experience with similar projects

Describe the methodology used to develop this project's contingency

Project complexity

Scope confidence

Uncertainty allowances

Describe the methodology used to develop this project's escalation rate

Assumed annual escalation rate
Assumed expenditure curve

Linear extrapolation

Capitalizable spare parts and materials identified and estimated

Training and start-up costs estimated

Non-consumable process chemicals; e.g., catalysts, coolants, identified and
estimated

FEL WORKSHOP – CONFIDENTIAL 22 IPA, Inc.