Engineering Design QA

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 Workflow (EDIW):.................................................................................................................................................................................................... 2
Phase 1 Scope Definition and Engineering Execution Strategy - PROPOSAL ................................................................................................................................................ 3
Phase 2 Commencement of Detail Design – SITE VISIT ......................................................................................................................................................................................... 5
Phase 3 Initial Design Development and Hazard Identification – 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 WORKflOW (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. Detailed Design Is Broken Into Seven Phases:
2. Scope Definition and Engineering Execution Strategy
3. Commencement of Detailed Design
4. Initial Design Development and Hazard Identification
5. Initial Design Review & Audit
6. Approval for Design
7. Approval for Construction
8. Design Close-Out
The workflow shown above illustrates the execution sequence of a generic Detail Design Project. Some work can be undertaken concurrently
however a sequential flow 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 identified and the necessary mitigation strategies to be put in place.
Renatus Engineering Quality Control Manager (QCM) will measure compliance with the workflow and ensure out-of-phase working is being
identified and managed. This document contains a copy of the Detail Design EDHW Workflow 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 sufficiently mature for detail design to
progress in a controlled and minimal change environment.
ACTIVITIES/DELIVERABLE DESCRIPTION DISCIPLINE SUPPORTING DOCUMENTATION
1 Level 1 - Engineering
Execution Strategy –
Proposal Documentation
2 FEED / AS BUILD
Validation
3 Project Baseline
Standards
4 Engineering Audit
Schedule
5 Level 2 - Engineering
Execution Plan &
Engineering
Organization Chart
6 Integrated Engineering
Systems
Review / confirm Engineering Execution Strategy ,
e.g. execution locations, workshare, disciplines
required, specialist support, etc.
Confirm 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
specifications are to be utilized, ie. Corporate,
project, client, and confirm procedure. Include in
Engineering Execution Plan and / or Discipline Job
Design Specifications.
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
Agree when it’s a team and determine when it’s a
single individual what engineering design tools to
be used and confirm that system hardware,
software and support is available. The customer
Project Manager
and Project
Engineering
Manager
Project
Engineering
Manager
Project
Engineering
Manager
Project
Engineering
Manager
Project
Engineering
Manager
Engineering
Systems and All
Disciplines
Proposal documentation and Project
Execution Plan (PEP)
Engineering Baseline Standards,
unified facilities guidance (UFG), other
design guides. (ie VA guidelines)
Technical Safety Events Schedule
(Lead Technical Safety Engineer), MS
project template should be developed.
Fins or develop an Engineering
Systems Project Start-up Manual,
Document No. OAGX160-170-MAN-
002
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7 Quantitative Risk
Assessment Strategy
8 Discipline Job Design
Specification
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 specifications.
Establish status of project Quantitative Risk
Assessment and confirm methodology for timely
delivery into engineering design process. Agree on
accountability for delivery, ie. Client, 3rd party,
Renatus, and record in Engineering Execution Plan.
Define the key project specific 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
9 Level 3 Engineering Plan 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.
10 Technical Risk Register 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.
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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 DESCRIPTION DISCIPLINE SUPPORTING DOCUMENTATION
1 Performance Standards &
Verification Scheme
2 Document Distribution
Matrix
3 Structural Integrity
Interface
Confirm 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
identified & visible to Project, ie Renatus / Client
focal points, Technical Authorities, Independent
Verification Bodies, etc.
4 Material Selection Report Report defining the requirements and
specifications of necessary material.
5 Hazard Management Plan 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.
6 Discipline Specifications Develop / confirm baseline specifications,
utilizing specintact specifications where possible.
7 PDMS Catalogues Ensure PDMS catalogues are populated &
available for all affected disciplines, utilizing
online search (making sure to convert data to
generic standards), where possible.
Technical Safety
Project
Engineering
Manager
Structural
Discipline
Technical Safety
ALL.
ALL
Develop and find Hazard Management
Philosophy, Hazard & Risk
Management,; Design Verification
Activities ; Platform Safety Case.
Material Engineering Selection.
Develop of find: Hazard & Risk
Management,; Management of
Functional Safety Guideline
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PHASE 3 INITIAL DESIGN DEVELOPMENT AND HAZARD IDENTIfiCATION – 10%
To develop initial design deliverables to Inter Discipline Review stage and identify key hazards.
ACTIVITIES/DELIVERABLE DESCRIPTION DISCIPLINE SUPPORTING DOCUMENTATION
1 Hazard Identification Perform hazard identification studies, as
identified on Engineering Audit Schedule /
Technical Safety Events Schedule.
2 Environmental Issue
(NEPA)
Formal assessment of environmental aspects
associated with a modification or a change, and to
propose prevention or mitigating measures.
3 System and Process
Diagram
Issue System and Process Flow / control
Diagrams on formal Inter-Discipline Review.
4 Plot Plans / Layouts Issue equipment Plot Plans / Layouts on formal
inter-Discipline Review.
5 Equipment List 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.
6 Mechanical Handling
Strategy
Develop Mechanical Handling Strategy including
general approach / constraints, platform crane
limits, installation philosophy, operation and
maintenance, etc.
Technical Safety
Technical Safety
Mechanical and
Electrical
Mechanical and
Electrical
Mechanical and
Structural
Develop or Reference: Environmental
Impact Identification Engineering &
Design Reviews manual
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To confirm that the initial design development is strong.
PHASE 4 INITIAL DESIGN REVIEW AND AUDIT – 35%
ACTIVITIES/DELIVERABLE DESCRIPTION DISCIPLINE SUPPORTING DOCUMENTATION
1 Hazardous Area Review Formal Engineering discipline review of
hazardous area layouts to confirm requirements
for the correct selection and location of
equipment.
2 Special design
consideration Review
3 Plot Plans / Layout / 3-D
Model Review
Formal Engineering unique process or system to
confirm 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.
4 LEED Review Formal review of ?????????????
5 Technical Audit Obtain confirmation, by sampling of project
documentation, that the engineering of the project
is to the required standard and free from errors.
Technical Safety
Process, Piping,
Technical Safety,
Instruments
Structural,
Mechanical,
Electrical,
Independent
(Renatus QA
Engineering)
Hazard and Risk Management
Procedure; Engineering & Design
reviews,
Engineering & Design Reviews,
Engineering & Design Reviews,
Technical Audit Procedure
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PHASE 5 DESIGN APPROVAL – 35% RETURN
To ‘Freeze’ the process design, and develop dependent design & procurement activities.
ACTIVITIES/DELIVERABLE DESCRIPTION DISCIPLINE SUPPORTING DOCUMENTATION
2 Operability 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.
3 OSHA & NEPA Audit 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.
4 Environmental Report Issue final report to document & confirm that the
design has considered all applicable
environmental aspects & demonstrates that
design controls have been included to minimize /
control the environmental impact.
5 Constructability Review Conduct formal Constructability Reviews to
ensure safe and efficient installation of equip.
Process,
Technical Safety
Technical Safety
Technical Safety
(COTR/CM)
10 Holds Register Develop register to record & manage design holds. Engr Manager
15 Process Assurance Conduct process studies to demonstrate the
process design under a range of conditions, ie
equipment start-up, etc.
Process
16 Verification of Vendor
Information &
Certification - Design
Completion
Verify, primarily through review of vendor
documentation, that their design & manufacture
of fabricated packages, etc is robust and contains
sufficient information to facilitate completion of
affected Renatus discipline design.
17 Compliance Report Issue final report as documented confirmation
that the design meets the requirements of the
10% review
Affected
disciplines
Technical Safety
Find links
Engineering & Design Reviews,
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PHASE 6 APPROVAL FOR CONSTRUCTION - 90%
To ensure that sufficient design information & certification is available to facilitate safe installation, operation & maintenance.
ACTIVITIES/DELIVERABLES DESCRIPTION KEY DISCIPLINE SUPPORTING DOCUMENTATION
2 Customer Compliance Final report to formally demonstrate that the Instruments
Report
system comply with the requirements.
4 Cost Report Cost estimate. Affected
Disciplines
5 Construction Specification Approved For Construction report. Affected
Disciplines
9 Construction Drawings Approved For Construction report. Affected
Disciplines
10 Verification of Vendor
Information &
Verify, primarily through review of vendor
documentation, that their design & manufacture
Affected
Disciplines
Certification - Installation,
Operation & Maintenance
of fabricated packages, etc is robust and contains
sufficient information to facilitate safe installation,
operation & maintenance.
11 Design Certifi cates Applicable consultant provide seals
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PHASE 7 DESIGN CLOSE-OUT
To ensure all final design deliverables are completed and that client and statutory obligations are satisfactorily resolved.
ACTIVITIES/DELIVERABLES DESCRIPTION KEY DISCIPLINE SUPPORTING DOCUMENTATION
1 Transmittal letter Submit deliverable to customer. Affected
Disciplines
2 Certifying Authority (CA)
/ Independent
Verification Bodies (IVB)
Acceptance
Close out all outstanding technical queries and
obtain final Letter of Acceptance.
Affected
Disciplines
3 Complete Project As-
Built Documentation
Complete as-builts of design drawings and
deliverables in accordance with Project / Client
requirements.
Affected
Disciplines
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