Deliverables List For Projects in The Fertilizer Industry: Document Development Guidance

Deliverables list for Projects in the
fertilizer industry
Document Development Guidance

Department: Projects / Engineering
Revision 1 – August 2018
Doc. No: AKH01-GUI-ENG-LST-001

Deliverables list for Projects in the fertilizer industry
Contents
1. Synopsis .............................................................................................................................................. 2
2. Why develop specific guidelines and procedures ......................................................................... 3
3. Purpose of this document ................................................................................................................. 3
4. Project and Document Phases......................................................................................................... 3
5. Deliverables of Identify Phase .......................................................................................................... 4
6. Deliverables for Select Phase .......................................................................................................... 4
7. Deliverables for Define Phase .......................................................................................................... 6
8. Deliverables for Execute Phase ..................................................................................................... 14
9. Deliverables for Operate Phase .................................................................................................... 23
10. Applicability ................................................................................................................................... 24
11. Responsibility ................................................................................................................................ 24
12. Develop your own organization procedures ............................................................................. 24
13. Definitions ...................................................................................................................................... 25
1
1. SYNOPSIS
AmmoniaKnowHow.com and UreaKnowHow.com support fertilizer manufacturers by providing essential
services to the industry, using our syngas technologies and scientific knowledge developed in multiple
projects worldwide.
Together we initiate a program to enhance the guidelines and procedures for operation, engineering,
maintenance and process safety in the fertilizer industry utilizing the best practices and standards
available today.
Using knowledge gained from our industry, historic risk registers, lessons learned from projects and from
FIORDA members we are committed to give proper advice to improve safety, reliability and projects
performance of fertilizer plants.
2
2. WHY DEVELOP SPECIFIC GUIDELINES AND PROCEDURES

Guidelines and Procedures are developed to help staff and management teams run the organization. In
the best use situations, procedures play a strategic role in an organization. They are developed in light of
the mission and objectives of the company and they become the media by which management’s plans,
rules, intents, and business and operation processes become documented and communicated to all staff.
Carefully drafted and standardized guidelines and procedures save the company countless hours of
management time. Guidelines, procedures and employee handbook should be an important part of the
operation. They should be the first thing given to a new employee (either in hard copy or an electronic
version). They should also be easily accessible in their most up-to-date version. Hence it is extremely
important that an organization’s procedures are a “living document” prepared and saved in Microsoft
Word and easily exported into portable versions (like PDF) and made available over the company
network.
3. PURPOSE OF THIS DOCUMENT

Purpose of the Deliverables List for Projects is to define the basic level of documentation required for
each phase of the project and to determine the level of responsibility for each engineering discipline
during the review phase of each document.
Deliverables List for Projects document can be used as internal guideline by fertilizer manufactures
providing contractors and consultants with clear requirements of deliverables for each project stage.
4. PROJECT AND DOCUMENT PHASES

In general, a project is divided in 5 phases:
1. Identify
2. Select
3. Define
4. Execute
5. Operate
The number of documents, complexity and level of details increase for each phase while the project
progresses. The status of deliverables changes and can be defined as following:
Preliminary Work on the deliverable has started; development is typically limited to sketches, rough
outlines or similar levels of early completion;
Baseline A Baseline status refers to a level of maturity that is sufficient for a clear definition of the
part of the engineering work covered by the document. This also comprises refinement of
the Preliminary status as well as cross-functional reviews being conducted. Further
Updated is required prior to Finalization / actual implementation.
Updated An Updated status refers to level of maturity, in which the Baseline document has been
further developed and aligned cross-functionally. Final stage has not yet been reached.
More than one updating cycle may be necessary.
AFD "Approved for Design": Engineering work has gone through appropriate steps of review
and assurance, enabling the design to be frozen. Commencement of detail-design is the
following step. Any significant modification of the Final document can only be achieved
through formal "Management of Change" process (MoC)."
3
Final A Final status refers to a level of maturity that is sufficient to proceed with implementation
of the engineering work. A deliverable having achieved a Final status shall not require
change in the further course of the implementation. Any significant modification of the
Final document can only be achieved through formal "Management of Change" process
(MoC).
Applicable Document is issued for the specific project life cycle phase and does not require Update
in next phases.
5. DELIVERABLES OF IDENTIFY PHASE

During the Identify phase the disciplines involved in the project are in general the Project Management,
Process and Mechanical. The status of documentation is Preliminary and Baseline and will include
process basic functionality of plant, type of plant, basic function, basic interconnection to plant
environment (technical, economic, environmental).
Examples of deliverables to be developed in the Identify phase are:
- Milestone Plan
- Risk Management Plan + Risk Register
- Conceptual HAZID study
- Time Schedule
- Basis of Design
- Condition Assessment Studies / Report
- Pipeline (ISO-metrics) - general route profile
- Block Flow Diagrams
- Equipment List
- Heat and Material Balances
- Process Design Criteria Document
- Process Flow Diagrams
- Simulation Models, reports and listings
- Tie in List
- Fluid List
- Authority Management Plan (Permits and Consents Strategy)
- Site Identification Report
- Stakeholder Register & engagement plan
- Etc.
6. DELIVERABLES FOR SELECT PHAS E

The primary objective of the Selection phase is to demonstrate that the project will provide an acceptable
level of risk and financial return as a sound investment for Client. The technical, commercial and financial
aspects of the project will be assessed to select the optimal / preferred development and provide a robust
case for progressing towards project realisation.
In the Select phase more engineering disciplines are getting involved. Civil, Control & Instrumentation,
Electrical, HSE, Cost Control will have their own deliverables together with Mechanical, Process and
Project Management.
Document status may vary, depending on discipline for example:
Discipline Deliverable Title Document status
Civil Geotechnical Report Preliminary
4
Control & Instr. I/O List Preliminary
Control & Instr. Instrument Index Preliminary
Control & Instr. Control System Architecture Diagram Preliminary
Electrical Electrical Equipment List Preliminary
Electrical Electrical Key Single Line Diagram Preliminary
Electrical Electrical Load List Preliminary
General Eng. Design Philosophies for all Disciplines Preliminary
General Eng. General Arrangement Drawings Preliminary
HSSE Leak Detection Instrument Index Preliminary
HSSE Detailed HAZID study Preliminary
HSSE Coarse HAZOP study Preliminary
HSSE Hazard and effects register Preliminary
HSSE Design HSE case concept including ALARP demonstration Preliminary
HSSE Draft Emergency Response plan Preliminary
Mechanical Calculation Notes for Equipment Preliminary
Mechanical Corrosion and material selection philosophy Preliminary
Mechanical Mechanical Equipment drawings Preliminary
Process Piping & Instrumentation Diagrams Preliminary
Process Process Equipment and Systems Datasheets Preliminary

Process Equipment and Systems Specifications including
Process Preliminary
Utility
Process Operation and Control Philosophy Preliminary
Process Isolation Philosophy Preliminary
Process ESD and DCS Philosophy Preliminary

Project
Compliance Register and regulatory action plan Preliminary
Management
Civil Civil Works Specification(s) Baseline
Civil Technical Report Baseline
Civil Geotechnical Data Acquisition Plan Baseline
General Eng. Basis of Design Baseline
General Eng. Condition Assessment Studies/ Report Baseline
5
General Eng. General Plant Layout (Plot Plan) Baseline
Mechanical Rotating Equipment Drive Selection Study Report Baseline
Process Equipment List Baseline
Process Fluids List Baseline
Process Heat and Material Balances Baseline
Process Process Flow Diagrams Baseline
Process Simulation Models, reports and listings Baseline

Project Authority Management Plan (Permits and Consents
Baseline
Management Strategy)
Project
Risk Management Plan + Risk Register Baseline
Management
Process Block Flow Diagrams Updated
Process Tie in List Updated

Project
Milestone Plan Updated
Management
Project
Project Reports Updated
Management
Project
Time Schedule Updated
Management
General Eng. Basis of Design (non-process) Final
General Eng. Operation & Maintenance Philosophy Final
General Eng. Spare Parts Strategy Final
Process Process Design Criteria Documents Final

Project
Scope of Work for Project Final
Management
Project Services Cost Estimates Applicable
Project
Risk Register Applicable
Management
Others…
7. DELIVERABLES FOR DEFINE PHAS E

Define phase means the project work following the select phase and successful FEED Readiness Review
and culminating in a FID submission documentation.
In this phase, the requirements that are associated with the project result are specified as clearly as
possible. This involves identifying the expectations that all the involved parties have with regard to the
project result.
It is important to identify the requirements as early in the process as possible. Wijnen (2004) distinguishes
several categories of project requirements:
6
• Preconditions
• Functional requirements
• Operational requirements
• Design limitations
Civil Architectural Drawings for Buildings Baseline
Civil Civil Works Specification(s) Final
Civil Technical Report Final
Civil Construction Drawings Baseline

Entire list of Deliverables and Engineering RACI Matrix is
Civil available only for AmmoniaKnowHow.com & Baseline
UreaKnowHow.com clients



Civil available only for AmmoniaKnowHow.com & Final

Control & Instr. I/O List Baseline
Control & Instr. Instrument Index Baseline
Control & Instr. Control System Architecture Diagram Baseline
Control & Instr. Process Control Narrative Baseline
Control & Instr. Cause & Effect Diagram Baseline
Control & Instr. Control System Specification Baseline

Control & Instr. available only for AmmoniaKnowHow.com & Baseline
7














8


Electrical Electrical Equipment List Baseline
Electrical Electrical Key Single Line Diagram Final
Electrical Electrical Load List Baseline
Electrical Cable Routing/overhead line plans Baseline

Electrical available only for AmmoniaKnowHow.com & Final

Electrical available only for AmmoniaKnowHow.com & Baseline



Electrical available only for AmmoniaKnowHow.com & Preliminary


Electrical Typical installation drawings Preliminary
Electrical Electrical cables List Baseline
Electrical Cathodic Protection System Specification Baseline

9

Electrical (ATEX) Hazardous Areas: Risks assessment of explosions Preliminary

Electrical (ATEX) available only for AmmoniaKnowHow.com & Baseline

Electrical (ATEX) available only for AmmoniaKnowHow.com & Preliminary
General Eng. Condition Assessment Studies/ Report Updated
General Eng. General Arrangement Drawings Final

General Eng. available only for AmmoniaKnowHow.com & Final

General Eng. available only for AmmoniaKnowHow.com & Final

General Eng. available only for AmmoniaKnowHow.com & Baseline
General Eng. Basis of Design Final
HSSE Identify major risks for C&C (joint SIMOPS and HAZID) Baseline
HSSE Construction HSSE readiness review Updated
HSSE Preliminary Bow-tie analyses Preliminary
HSSE Design HSE case including ALARP demonstration Updated
HSSE MAH Report Updated
HSSE HAZOP study Baseline
HSSE LOPA study Baseline
HSSE Design Safety Review Baseline
HSSE SIMOPS study Baseline

HSSE available only for AmmoniaKnowHow.com & Baseline
10









Mechanical Calculation Notes for Equipment Baseline
Mechanical Corrosion and material selection philosophy Baseline

Mechanical datasheets (process & utilities equipment,
Mechanical Baseline
piping, valves)
Mechanical Mechanical General Arrangement Drawings Baseline
Mechanical Specifications (process & utilities equipment,
Mechanical Baseline
piping, valves)
Mechanical Pressure vessels drawings Preliminary
Mechanical Piping Calculations Baseline
Mechanical Piping Classes Specification Baseline

Mechanical available only for AmmoniaKnowHow.com & Final
11


Mechanical available only for AmmoniaKnowHow.com & Preliminary




Process Vessels Sizing Final
Process Draining philosophy Baseline
Process Equipment List Final
Process Flaring and Blow Down Philosophy Final
Process Fluids List Final

Process available only for AmmoniaKnowHow.com & Final




12




Process Process Flow Diagrams Final
Process Draining Philosophy Final
Process Operation and Control Philosophy Final
Process Isolation Philosophy Final
Process ESD and DCS Philosophy Final
Process Commissioning & Start up Philosophy Final
Project Services Contingency Estimation Applicable
Project Services Cost Breakdown Structure Applicable

Project Services available only for AmmoniaKnowHow.com & Applicable


Project Services available only for AmmoniaKnowHow.com & Updated


13



Project Authority Management Plan (Permits and Consents

Final
Management Strategy)
Project
Compliance Register and regulatory action plan Updated
Management
Project
Milestone Plan Final
Management
Project
Management
Project
Risk Management Plan + Risk Register Applicable
Management
Project
Management
Project available only for AmmoniaKnowHow.com & Updated
Management UreaKnowHow.com clients

Project available only for AmmoniaKnowHow.com & Updated
Management UreaKnowHow.com clients
8. DELIVERABLES FOR EXECUTE PHASE

In this phase all documents shall be sufficient for the execution phase and checked by an appropriate
certified body.
Each deliverable shall have a high level of detail and fulfill the purpose for it is produced.
Civil Architectural Drawings for Buildings Final
Civil Construction Drawings Final
Civil Layouts Final
Civil BoQ's and MTO Final
Civil Calculation Report Final

14



Control & Instr. available only for AmmoniaKnowHow.com & Final






Control & Instr. Local Control System Specification Final
Control & Instr. Field Instruments Specification Final


Control & Instr. Control Room Specification Final
Control & Instr. Instrumentation Cables Specification Final
Control & Instr. Control Room Layout Drawings Final
Control & Instr. Cable Block Diagram Final
15







Control & Instr. Logic Diagrams Final
Control & Instr. Electrical/ Hydraulically/ Pneumatic Layouts for Instruments Final
Control & Instr. Panel, Cabinet and Desk Layout Drawings Final




Electrical Operating philosophy for the power system Final
16
Electrical Electrical equipment specifications Final



Electrical available only for AmmoniaKnowHow.com & Applicable








Electrical Schedule of protective relaying settings Applicable
Electrical Material take off for all electrical equipment material Applicable
Electrical Cathodic Protection System Specification Final
Electrical Electrical Calculations (LV) Final
Electrical Electrical Block Diagrams Final
17


Electrical (ATEX) available only for AmmoniaKnowHow.com & Final

Electrical (ATEX) Hazardous Areas Drawing Final
Electrical (ATEX) Hazardous Areas: Equipment specifications Final

Hazardous Areas: Materials characteristics, including
Electrical (ATEX) Final
electrical resistivity
Electrical (ATEX) Hazardous Areas: Certificate EC Final
Electrical (ATEX) Hazardous Areas: Declaration of conformity EC Final

Manufacturer's Declaration for equipment which have not
Electrical (ATEX) own source of ignition and are considered outside the Final
scope of Directive 94/9/EC
Documents for Ex equipment with conditions of use, e.g.
Electrical (ATEX) for equipment with certificate numbers which have the Final
suffix „X‘






18

Electrical (ATEX) Hazardous Areas: Report regarding initial inspection Final
Electrical (ATEX) Hazardous Areas: Information for Maintenance and repairs Final
Electrical (ATEX) Explosion Protection Document Final

General Eng. Condition Assessment Studies / Report Final
General Eng. Operations Readiness Review Final

HAZID and HSSE risk assessment (for Construction &
HSSE Final
Commissioning) - joint SIMOPS and HAZID
HSSE Construction HSSE readiness review Final
HSSE Detailed Bow-tie analyses Final

HSSE available only for AmmoniaKnowHow.com & Final




HSSE Fire and Explosion Analysis Final
HSSE Emergency System Survivability Analysis Final
HSSE SIL study/ classification Final
HSSE HSSE Management plan (for construction phase) Final

Independent verification of safety critical process control
HSSE Final
loops
19









HSSE Leak Detection System Wiring Diagram Final
Mechanical Calculation Notes for Equipment Final
Mechanical Corrosion and material selection Philosophy Final
Mechanical Coating, painting and insulation specifications Final



20







Mechanical Tie-in details Final
Mechanical Piping support schedule Final
Mechanical Piping support details Final
Mechanical Hydrostatic test diagram Final





21

Mechanical Pressure vessels internal arrangement drawings Final
Mechanical Welding specifications and procedures Final
Mechanical Typical welding detail drawings Final











Mechanical De-watering and drying specification Final
22
Project Services Contingency Estimation Applicable
Project Services Cost Breakdown Structure Applicable
Project Services Progress Measurement System Applicable



Project Services available only for AmmoniaKnowHow.com & Final




Project Services Work Breakdown Structure Applicable

Project
Compliance Register and regulatory action plan Final
Management
Project
Management
Project
Risk Management Plan + Risk Register Applicable
Management
Project
Management
Project
Stakeholder Register & -engagement plan Updated
Management
Project
Time Schedule Updated
Management
9. DELIVERABLES FOR OPERATE PHASE
23
HSSE HSSE Management System Final
10. APPLICABILITY
Deliverables List for Projects is a document owned by the Projects / Engineering department within the
organization. They are responsible to assess the necessity of each deliverable depending on project
complexity and scope of work.
11. RESPONSIBILITY
A detailed RACI Matrix shall be developed for the following engineering disciplines:
- Process Engineering
- Electrical Engineering
- Control & Instrumentation Engineering
- Civil Engineering
- Static Equipment
- Rotating Equipment
- Piping, Valves & Pipeline Engineering
- HSSE
- Project Management
- Project Services (Cost Estimating & engineering)
- Project Services (Planning & scheduling)
Responsibilities can be defined as following:
(R) Responsible The accountable person may delegate some of his/her tasks to the responsible
person, who then is in charge to achieve this task. The responsible person is the
one who delivers the content of a document ("doer").
(A) Accountable The one who is ultimately in charge of completion of the deliverable or task -
there is only one accountable person per deliverable / task and this person
approves this deliverable.
(C) Consulted Sought for their opinion, the consulted person bears expertise to share within the
creation process of the deliverable / task.
(I) Informed Stakeholders to be directly informed are marked as such to be kept up-to-date
upon approval of the deliverable / completion of the task.
12. DEVELOP YOUR OWN ORG ANIZATION PROCEDURES

Although templates can give you a head start on procedures development, other factors must be
considered as you write your own internal documents.
One factor is your organization’s culture. Organizational attitudes toward procedures determine the
spectrum. On one end of the scale are companies that have a procedure for everything. At the other end
of the spectrum are companies that only have only a few guidelines (only those required by the laws that
are relevant to that company). Most companies fall somewhere in between these two extremes. The
manager writing any guideline needs to understand where on the spectrum the company it falls and how
the policy can be made to fit the organization’s culture to enhance compliance.
24
Other two factors to be consider when developing guidelines and procedures are the fertilizer technology
that company employs and local and international standards applicable to the industry. Internal standards
and procedures must be developed in line with these factors, being applicable for your own plants and in
line with regulatory requirements.
The last, but not least, factor when developing your own procedures is the best industry practice that you
need to employ. Liaison with your fertilizer association, participation in industry meetings and conferences
and using fertilizer industry consultants can bring a fresh eye, new ideas and enhance the quality of your
own guidelines and procedures.
13. DEFINITIONS
AFD Approved for Design
ALARP As Low As Reasonable Practicable
ATEX Atmospheres Explosible
BoQ Bill of Quantities
CCTV Closed Circuit TV
DCS Distributed Control System
ESD Emergency Shut Down
FEED Front End Engineering Design
FID Final Investment Decision
FIORDA Fertilizer Industry Operational Risks Database
HAZID Hazard Identification Study
HAZOP Hazard and Operability Study
HSE Health Safety Environmental
HSSE Health, Safety, Security and Environmental
HV High Voltage
LOPA Layer of Protection Analysis
LV Low Voltage
MAH Major Accident Hazards
MOC Management of Change
MTO Material Take Off
MV Medium Voltage
NDT Non-Destructive Test
25
SIL Safety Integrity Level
SIMOPS Simultaneous Operational Studies
Disclaimer
The information contained in this document is given in good faith and while every care has been taken in preparing these documents,
UreaKnowHow.com and AmmoniaKnowHow.com make no representations and give no warranties of whatever nature in respect of these documents,
including but not limited to the accuracy or completeness of any information, facts and/or opinions contained therein. Both companies, its subsidiaries,
the directors, employees and agents cannot be held liable for the use of and reliance of the opinions, estimates, forecasts and findings in these
documents.
26
Fertilizer Industrial Services Ltd
Venture House, Arlington Square
Downshire Way, Bracknell, RG12 1WA, UK
P: + 44 (0) 7494 783 534
Web: www.fertilizer.services
E-mail: [email protected]

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Deliverables list for Projects in the

Document Development Guidance

Doc. No: AKH01-GUI-ENG-LST-001

2. WHY DEVELOP SPECIFIC GUIDELINES AND PROCEDURES

3. PURPOSE OF THIS DOCUMENT

4. PROJECT AND DOCUMENT PHASES

5. DELIVERABLES OF IDENTIFY PHASE

Examples of deliverables to be developed in the Identify phase are:

6. DELIVERABLES FOR SELECT PHAS E

Document status may vary, depending on discipline for example:

Discipline Deliverable Title Document status

Civil Geotechnical Report Preliminary

Control & Instr. I/O List Preliminary

Control & Instr. Instrument Index Preliminary

Control & Instr. Control System Architecture Diagram Preliminary

Electrical Electrical Equipment List Preliminary

Electrical Electrical Key Single Line Diagram Preliminary

Electrical Electrical Load List Preliminary

General Eng. Design Philosophies for all Disciplines Preliminary

General Eng. General Arrangement Drawings Preliminary

HSSE Leak Detection Instrument Index Preliminary

HSSE Detailed HAZID study Preliminary

HSSE Coarse HAZOP study Preliminary

HSSE Hazard and effects register Preliminary

HSSE Design HSE case concept including ALARP demonstration Preliminary

HSSE Draft Emergency Response plan Preliminary

Mechanical Calculation Notes for Equipment Preliminary

Mechanical Corrosion and material selection philosophy Preliminary

Mechanical Mechanical Equipment drawings Preliminary

Process Piping & Instrumentation Diagrams Preliminary

Process Process Equipment and Systems Datasheets Preliminary

Process Isolation Philosophy Preliminary

Process ESD and DCS Philosophy Preliminary

Civil Technical Report Baseline

Civil Geotechnical Data Acquisition Plan Baseline

General Eng. Basis of Design Baseline

General Eng. Condition Assessment Studies/ Report Baseline

General Eng. General Plant Layout (Plot Plan) Baseline

Mechanical Rotating Equipment Drive Selection Study Report Baseline

Process Equipment List Baseline

Process Fluids List Baseline

Process Heat and Material Balances Baseline

Process Process Flow Diagrams Baseline

Process Simulation Models, reports and listings Baseline

Process Tie in List Updated

General Eng. Operation & Maintenance Philosophy Final

General Eng. Spare Parts Strategy Final

Process Process Design Criteria Documents Final

7. DELIVERABLES FOR DEFINE PHAS E

Discipline Deliverable Title Document status

Civil Architectural Drawings for Buildings Baseline

Civil Civil Works Specification(s) Final

Civil Technical Report Final

Civil Construction Drawings Baseline

Entire list of Deliverables and Engineering RACI Matrix is

Entire list of Deliverables and Engineering RACI Matrix is

Entire list of Deliverables and Engineering RACI Matrix is

Entire list of Deliverables and Engineering RACI Matrix is

Control & Instr. I/O List Baseline