Detailed Engineering Design Phase

Engineering Design Integrity Workflow

Introduction
Detailed Design Engineering Design
Integrity Workflow (EDIW)
EDIW is AMEC’s best practice guidance to Engineering Managers and supporting
personnel for the delivery of technical integrity. It is an ‘aide-memoir’ that highlights
the key deliverables and activities throughout the lifecycle of a typical Detailed Design
project.
Detailed Design is broken into seven phases:

1 Scope Definition and Engineering Execution Strategy

2 Commencement of Detailed Design

3 Initial Design Development and Hazard Identification

4 Initial Design Review & Audit

5 Approval for Design (AFD)

6 Approval for Construction (AFC)

7 Design Close-Out

The workflow shown in the EDIW Road Map illustrates the execution sequence on a generic
Detail Design Project. The vertical columns show activities that can be undertaken concurrently
whilst the sequential flow of work is across the Road Map. 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 be done out of sequence, typically to meet a
demanding project schedule. Use of the EDIW allows the risks of out-of-sequence working to be
identified and the necessary mitigation strategies to be put in place.

AMEC’s corporate governance and assurance of Engineering will measure compliance with the
EDIW workflow and ensure out-of-phase working is being identified and managed. This document
contains a copy of the Detail Design EDIW Workflow Road Map and includes detailed descriptions of
the activities, the key engineering disciplines and supporting documentation.

1
Phase 1
Scope Definition and Engineering Execution Strategy
Preparation for commencement of detail design. To evaluate FEED deliverables to ensure
engineering is sufficiently mature for detail design to progress in a controlled and minimal
change environment. To confirm Engineering Execution Plan.

Key
Activities / Deliverables Description Supporting Documentation
Discipline
Project
Review / confirm Engineering Execution Strategy, e.g. Manager
Engineering Tender documentation, Project Execution Plan
1 Execution Strategy
execution locations, workshare, disciplines required, and Project
(PEP)
specialist support, etc. Engineering
Manager
Confirm maturity of Front End Engineering Design. Identify Project
Feed / BoD
2 Validation
any areas of concern and ensure these are captured on the Engineering
Technical Risk Register. Manager
Establish which codes, standards and specifications are to be
Project Engineering Baseline Standards, Document No.
Project Baseline utilised, eg. Corporate, project, client, and confirm procedure.
3 Standards Include in Engineering Execution Plan and / or Discipline Job
Engineering OAG-X160-190-GDL-012 (previously
Manager AOD-92-043 )
Design Specifications.
Create formal schedule to identify when technical integrity
Project
Engineering Audit audits, design reviews, HAZIDS, HAZOPS, etc are to be carried Technical Safety Events Schedule
4 Schedule out. Align to Level 3 Engineering Plan and include in
Engineering
(Lead Technical Safety Engineer)
Manager
Engineering Execution Plan.
Engineering
Project
Execution Plan & Create Engineering Execution Plan complete with key
5 Engineering supporting documents / information.
Engineering
Manager
Organisation Chart
Agree engineering design tools to be used and confirm
that system hardware, software and support is available. Engineering
Integrated
Include issues such as PDMS or PDS, Cats and Specs, survey Systems Engineering Systems Project Start-up Manual,
6 Engineering
methods, dimensional control techniques, etc. Document and and All Document No. OAGX160-170-MAN-002
Systems
record in the Engineering Execution Plan and discipline job Disciplines
design specifications.
Establish status of project Quantitative Risk Assessment
(QRA), Fire Risk Assessment (FRA) and Emergency Escape & Hazard Management Philosophy, OAG-X160-
Rescue Assessment (EERA) information and confirm Technical 190-GDL-009 (previously AOD-97-001):
7 QRA & FRA Strategy
methadology for timely delivery into engineering design Safety Hazard & Risk Management, OAG-X160-190-
process. Agree accountability for delivery, eg. Client, 3rd PRO-024
party, AMEC, and record in Engineering Execution Plan.
Define the key project specific design parameters and
operational constraints that are applicable to the appropriate
Discipline Job
8 Design Specification
discipline for the detailed design of the project. To identify key All Disciplines
individuals, roles and responsibilities, design tools, key codes
and standards, etc.
Agree work breakdown structure, develop CTRs and create
Level 3
9 Engineering Plan
level 3 integrated engineering plan covering all disciplines. To All Disciplines
be included in Engineering Execution Plan.
Corporate CE Compliance Strategy OAG-
X160-190-MAN-001; Project Compliance with
Pressure Equipment Regulations OAG-X160-
050-PRO-001; Pressure Equipment
Review and confirm strategy for CE Compliance . Ensure Project Regulations Guidelines AOD-97-047; ATEX
Confirm CE
10 Compliance Strategy
discipline Lead Engineers are aware of their responsibilities Engineering Guidelines, OAG-X160-190-GDL-003; Machinery
and appropriate resources / measures are in place. Manager Directive Guidelines, O&G-ENG-REP-29-001;
Electromatic Compatibility Regulations
Guidelines, OAG-X160-190-GDL-003; MC, The
Electrical Equipment (Safety) Regulations
Guideleines, OAG-X160-190-GDL-003.

Technical Risk Create formal Technical Risk Register identifying all possible
11 Register risks asscociated with the engineering design.
Techncal Safety

2
Phase 2
Commencement of Detail Design
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.
Key
Activities / Deliverables Description Supporting Documentation
Discipline
Confirm safety critical systems / elements and set Hazard Management Philosophy, OAG-X160-
Performance appropriate performance standards. i.e. functionality, 190-GDL-009 (previously AOD-97-001); Hazard
Technical
1 Standards & reliability and survivability. Develop scheme to allow the
Safety
& Risk Management, OAG-X160-190-PRO-024;
Verification Scheme independent competent body (ICB) to verify the design Design Verification Activities (under DCR),
against the performance standards. OAG-X160-190-PRO-028; Platform Safety Case.
Create formal document distribution matrix to ensure all Project
Document
2 Distribution Matrix
disciplines & departments receive all necessary design Engineering
information in a timely manner. Manager
Ensure structural integrity interfaces are identified & visible
Structural Integrity
3 Interface
to Project, e.g. AMEC / Client focal points, Technical Structural
Authorities, Independent Verification Bodies, etc.
Material Selection Report defining the requirements and specifications of AMEC Corporate Material Engineering
4 Report necessary material.
Metallurgy
Specifications.
Create Hazard Management Plan identifying all key hazards, Hazard & Risk Management, OAG-X160-190-
Hazard Management Technical
5 Plan
technical safety activities and the approach to managing
Safety
PRO-024; Management of Functional Safety
Major Accident Hazards (MAH) in the design. Guideline OAG-X160-190-GDL-004
Develop / confirm baseline piping specifications, utilising
6 Piping Specifications
AMEC Corporate specifications where possible.
Piping AMEC Corporate Piping Specifications.

Engineering
Systems,
supported by
Ensure PDMS catalogues are populated & available for all
Piping,
7 PDMS Calalogues affected disciplines, utilising AMEC Corporate data, i.e. CPC,
Electrical,
where possible.
Instruments,
Structural &
HVAC
Develop Control Monitoring and Safety Systems (CMSS)
Philosophy covering key instrumentation and control systems
8 CMSS Philosophy
e.g. Process Control System (PCS), Emergency Shutdown
Instruments
System (ESD) and Fire and Gas (F&G).

3
Phase 3
Initial Design Development and Hazard Identification
To develop initial design deliverables to Inter Discipline Review (IDC) stage and identify key hazards.

Key
Activities / Deliverables Description Supporting Documentation
Discipline
Perform hazard identification studies, as identified on Project Hazard Identification (HAZID) AOD-92-
Technical
1 HAZID Engineering Audit Schedule / Technical Safety Events
Safety
018; Engineering & Design Reviews, OAG-X160-
Schedule. 190-PRO-013.
Formal assessment of environmental aspects associated Environmental Impact Identification (ENVID)
Technical
2 ENVID with a modification or a change, and to propose
Safety
OAG-X160-190-PRO-121; Engineering & Design
prevention or mitigating measures. Reviews, OAG-X160-190-PRO-013.
Issue Process Flow Diagrams (PFD’s) on formal
3 PFD IDC
Inter-Discipline Review (IDC).
Process

Shutdown & Blowdown Explain the measures to prevent and control blowdown
4 Philosophy and how this will be achieved.
Process

Issue Piping & Instrumentation Diagrams (P&ID’s) on

5 P&ID’s IDC
formal Inter-Discipline Review (IDC).
Process

Issue Cause & Effects for formal Inter-Discipline Process and

6 C&E IDC
Review (IDC). Instruments
Issue equipment Plot Plans / Layouts on formal Piping and
7 Plot Plans / Layouts IDC
inter-Discipline Review (IDC). Layouts
Hazardous Area Issue Hazardous Area Layouts for formal Technical
8 Layouts IDC Inter-Discipline Review (IDC). Safety
Create master project equipment list identifying all
major items of tagged equipment, e.g. vessels, pumps,
9 Equipment List
motors, generators, hydrocycolnes, chemical injection
Mechanical
packages, electrical switchgear, control panels, etc.
Develop Mechanical Handling Strategy including general
Mechanical Handling Mechanical
10 Strategy
approach / constraints, platform crane limits, installation
and Structural
philosophy, operation and maintenance, etc.
Where required, i.e. where Corporate PMA’s or EAM’s
Particular Material PED Focal
11 Appraisals (PMA)
are not suitable, develop new PMA’s and obtain approval
Point
from Notified Bodies (NoBo’s).
Determine Fire & Explosion scenarios and identifies
Fire Risk Assessment Technical
12 (FRA)
requirements for prevention, control and mitigation
Safety
measures.
Emergency Escape &
Identify requirements for emergency escape & rescue, Technical
13 Resecue Assesment
e.g. lifeboats, escape routes, plant layout, etc Safety
(EERA)
Identify and assess the potential risks to drilling,
production, process equipment, and manned areas from
Technical
14 Dropped Object Study dropped or swinging objects. Where the consequence
Safety
of a dropped object is considered significant, to propose
prevention or mitigating measures.
Develop philosophy that assesses potential explosion
hazards and identifies appropriate blast loadings to be Technical
15 Blast Design Philosophy
applied to the engineering design process, eg. Vessels, Safety
pipe supports, structural steel, etc.
Develop philosophy that identifies requirements for
Technical
16 PFP / AFP Philosophy Passive Fire Protection (PFP) and/or Active Fire
Safety
Protection (AFP).
Initial review to establish requirements for a High Management of Functional Safety,
17 HIPPS Review
Integrity Pressure Protection System.
Instruments
OAG-X160-190-GDL-004

4
Phase 4
Initial Design Review and Audit
To confirm that the initial design development is robust.
Activities / Deliverables
1 Hazardous Area Review
P&ID Review and / or
2 ‘Initial Hazop’
Plot Plans / Layout / 3-D
3 Model Review
4 C&E Review
5 Technical Audit
5
Key
Description Supporting Documentation
Discipline
Formal Engineering discipline review of hazardous area Hazard and Risk Management Procedure
Technical
layouts to confirm requirements for the correct selection
Safety
OAG-X160-190-PRO-024; Engineering &
and location of equipment. Design reviews, OAG-X160-190-PRO-013
Process,
Piping, Formal Hazop, OAG-X160-190-PRO-017;
Formal Engineering discipline review of P&ID's to
confirm design basis.
Technical Engineering & Design Reviews, OAG-X160-190-
Safety, PRO-013
Instruments
Formal Engineering review of Plot Plans / Layouts. The Piping and
review shall ensure that the layout design complies with Layouts,
the required technical, safety, operability and Structural,
Engineering & Design Reviews,
maintainability standards. Makes sure the layout is cost Mechanical,
OAG-X160-190-PRO-013
effective, ensures the constructability of the work and Electrical,
agrees the layout basis on which the detailed design can Technical
proceed. Safety, Process
Hazard and Risk Management Procedure
Instruments,
Formal review of Cause & Effects diagrams to confirm OAG-X160-190-PRO-024; Engineering &
Process,
design basis and alignment with Hazard Management
Technical
Design reviews, OAG-X160-190-PRO-013;
Plan. Management of Functional Safety Guideline
Safety
OAG-X160-190-GDL-004
Obtain confirmation, by sampling of project Independent
Technical Audit Procedure
documentation, that the engineering of the project is to (Corporate
OAG-X160-190-PRO-022
the required standard and free from errors. Engineering)
Phase 5
Design Approval
To ‘Freeze’ the Process design, and develop dependent design & procurement activities.

Key
Activities / Deliverables Description Supporting Documentation
Discipline
Conduct initial PUWER assessment typically by review of Technical
PUWER Engineering & Design Reviews,
1 Assessments
PDMS model and/or vendor / equipment supplier information Safety,
OAG-X160-190-PRO-013
received to date. Mechanical
Dependent on Project updated P&ID’s and
C&E’s may be prepared from commented IDC’s
from Phase 3 Formal HAZOP, OAG-X160-190-
Hazard and Operability Studies, a systematic multi-discipline
Process, PRO-017 (previously AOD-92-022); Engineering
study based on the applications of guidewords to identify
2 HAZOP
causes of potential hazards and operability constraints in a
Technical & Design Reviews, OAG-X160-190-PRO-013
Safety - Note: additional HAZOP’s may be required,
facility.
i.e. earlier or later in the project. PEM to
consult with Process & Technical Safety Lead
Engineers.
SHE Audit ensures that the design obligations under The
SHE Audit Procedure OAG-X160-190-PRO-023;
Health and Safety At Work Act 1974 and project health, safety Technical
3 SHE Audit (AFD)
and environmental performance standards are being or have Safety
Engineering & Design Reviews, OAG-X160-190-
PRO-013
been met during the engineering and design processes.
Issue final report to document & confirm that the design has
Environmental considered all applicable environmental aspects & Technical Engineering & Design Reviews, OAG-X160-190-
4 Report demonstrates that design controls have been included to Safety PRO-013
minimise / control the environmental impact.
Affected
disciplines +
Constructability Conduct formal Constructability Reviews to ensure safe and Engineering & Design Reviews,
5 Review efficient installation of plant & equipment.
Construction /
OAG-X160-190-PRO-014
Implementa-
tion Group
Issue Approved For Design (AFD) Process and
6 P&ID AFD
Instrumentation Diagrams.
Process

7 C&E AFD Issue Approved For Design (AFD) Cause & Effects. Instruments

Process Data Sheets

8 AFD
Issue Approved For Design (AFD) Process Data Sheets. Process

Identify all HP / LP interfaces on formal register and ensure

HP / LP Interface
9 Listing
that all have been addressed satisfactorily via HAZOP’s and / Process
or individual reviews.
Engineering
10 Holds Register Develop register to record & manage post AFD design holds.
Manager
Conduct assessment to determine target Safety Integrity
Level (SIL). Note: Where the target SIL is 3, then it is likely
Management of Functional Safety,
11 SIL Assessments that a High Integrity Pressure Protection System (HIPPS) will Instruments
OAG-X160-190-GDL-004
be required. If the value is found to be 1 or 2, then a HIPPS
will not be required.
Conduct study to formally identify the performance
requirements of the High Integrity Pressure Protection Management of Functional Safety,
12 HIPPS Study
System (HIPPS) and demonstrate that it is robust. Should
Process
OAG-X160-190-GDL-005
include dynamic study for a range of transient conditions.
Conduct study to formally demonstrate that the High Integrity
HIPPS Reliability Pressure Protection System (HIPPS) complies with the Management of Functional Safety,
13 Study reliability & availability criteria for the Project, e.g. as
Instruments
OAG-X160-190-GDL-004
stipulated in the performance standards.
Conduct independent assessment to formally record that the Independent
SIL Achievement Management of Functional Safety, OAG-X160-
14 Report
target Safety Integrity Levels (SIL’s have been achieved) Must Competent
190-GDL-004
be completed prior to introduction of Hydrocarbons. Person (ICP)
Conduct flow assurance studies to demonstrate the process
15 Flow Assurance
design under a range of flow conditions, i.e. start-up to 100%.
Process

Verification of Verify, primarily through review of vendor documentation,

Vendor Information that their design & manufacture of fabricated packages, etc is Affected
16 & Certification - robust and contains sufficient information to facilitate disciplines
Design Completion completion of affected AMEC discipline design.

Issue final report as documented confirmation that the design

PFEER Technical
17 Compliance Report
meets the requirements of the Prevention of Fire and
Safety
Explosion, and Emergency Response (PFEER) Regulations

6
Phase 6
Approval for Construction (AFC)
To ensure that sufficient design information & certification is available to facilitate
safe installation, operation & maintenance.
Key
Activities / Deliverables Description Supporting Documentation
Discipline
Conduct SHE Audit at AFC stage in accordance with Technical
1 SHE Audit AFC
Harmonised Procedure. Safety
SHE Audit Procedure OAG-X160-190-PRO-023

Final report to formally demostrate that the Safety

IEC 61511 Management of Functional Safety, OAG-X160-
2 Compliance Report
Instrumented Systems comply with the requirements of Instruments
190-GDL-004
IEC 61511.
Issue Approved For Construction (AFC) Process Flow
3 PFD’s AFC
Diagrams.
Process

Operational Safety Technical

4 Case Development
Commence operational Safety Case development.
Safety
Issue Approved For Construction (AFC) Process and
5 P&ID’s AFC
Instrumentation Diagrams.
Process

Quantative Risk Complete QRA activities to confirm that the design is robust Technical
6 Assessment (QRA) and complies with legislative requirements. Safety

7 C&E AFC Issue Approved For Construction (AFC) Cause & Effects. Instruments

Operating Process, Formal HAZOP, OAG-X160-190-PRO-017

Ensure operating procedures are verified line by line against
8 Procedures Review
the facilities provided on the P&ID’s.
Technical (previously AOD-92-022); Engineering & Design
/ Operational HAZOP Safety Reviews, OAG-X160-190-PRO-013
Fabrication Issue Approved For Construction (AFC) Piping Isometrics, Affected
9 Drawings AFC Structural Steelwork drgs, etc. Disciplines
Verification of
Vendor Information Verify, primarily through review of vendor documentation,
& Certification - that their design & manufacture of fabricated packages, etc is Affected
10 Installation, robust and contains sufficient information to facilitate safe Disciplines
Operation & installation, operation & maintenance.
Maintenance
Where AMEC are deemed to be the manufacturer of the piping
EC Design Project Compliance with the Pressure
systems, then under the PED/PER, AMEC have to apply to the PER Focal
11 Examination
Notified Body (NoBo) for an EC Design Examination point
Equipment Directive, Document
Certificates No. OAG-X160-190-GDL-007.
Certificate (Cat IV assemblies only).
Where AMEC are deemed to be the manufacturer of the piping Project Compliance with the Pressure
Declaration of Project
12 Conformity
systems, then under the PED/PER, AMEC have to create a
Manager
Equipment Directive, Document
Declaration of Conformity, signed by the Project Manager. No. OAG-X160-190-GDL-007.

Phase 7
Design Close-Out
To ensure all final design deliverables are completed and that client and statutory obligations are
satisfactorily resolved.
Key
Activities / Deliverables Description Supporting Documentation
Discipline
Safety Case Submit Safety Case to HSE & close out all queries / Technical
1 Acceptance (HSE) correspondance prior to next stage of operations. Safety
Certifying Authority
(CA) / Independent Close out all outstanding technical queries and obtain final Technical
2 Verification Bodies Letter of Acceptance. Safety
(IVB) Acceptance
Complete
Complete as-builts of design drawings and deliverables in Affected As Built Drawings and Documentation,
3 Project As-Built
accordance with Project / Client requirements. Disciplines AOD-92-021
Documentation

AMEC (LSE: AMEC) is a focused supplier of high-value consultancy, engineering and project management services to the world’s natural resources, nuclear, clean energy, water and environmen-
tal sectors. With annual revenues of over £2.5 billion, AMEC designs, delivers and maintains strategic and complex assets for its customers. The company employs some 22,000 people in around
40 countries worldwide.

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