HIGH EFFICIENCY EQUIPMENT FOR FRENCH PROCESS

ZINC OXIDE MANUFACTURING

Detailed Design and Engineering Deliverable List

This listing is a typical engineering deliverables list for a zinc oxide manufacturing facility. The
actual deliverable list will be amended during the FEED process to reflect the actual details and the
proposed scope of the project. In many cases, the documentary requirements are met by issuing a
single document, such as a general arrangement drawing, showing battery limits, utility
connections and utility requirements etc.

P = Deliverables with the feasibility study

F = Deliverables with the FEED (Front End Engineering Design)

D = Final engineering deliverables (the column is omitted except for the P&ID data page)

Unmarked Items are deliverables at the completion of the Engineering Process (EPCM)

◆ Preliminary information

◆ Documentary requirements Complete

Introduction

Description of deliverable P F

◆
Introduction
◆ ◆
Statement of plant production targets and progressive implementation plan
◆ ◆
Site Description
◆
Client supplied data
◆
Project execution plan
◆
Document order and precedence
◆
Master document Index
◆
Engineering unit statement

A. H. Burns Energy Systems Ltd.

562 Main Street East, Hamilton. Ontario. Canada. L8M 1J2
Tel 905 525 6321 www.burnsenergy.ca
Feasibility
Description of deliverable P F

◆
Description of project
◆
Basis of design
◆
Preliminary equipment scope
◆
Shop space requirements
◆
Basic engineering design data
◆
Preliminary site plan
◆
Project codes and standards

Process Design
Description of deliverable P F

P F
Process safety documents
◆
Hazop report (Hazardous Operation)
◆
• Fire hazard report
◆
• Process flow diagrams (PFDs), Utility flow diagrams (UFDs) Heat & material
balance
◆
Process & operational control description
◆
Process equipment list
◆ ◆
Datasheets for main equipment (per equipment list)
◆
• Process design calculations
◆ ◆
• Line list (Process / Mechanical engineering database)
Tie-in schedule
Effluent and emission summary
◆ ◆
Mechanical handling report
◆ ◆
Noise data
◆
Performance guarantees statement
◆
Performance test procedure
Pre-commissioning and commissioning manual
Operating manual
PLANT DESIGN

Description of deliverable D P F

◆ ◆
Hazardous area classification drawings
◆ ◆
Plant block flow diagram
◆ ◆
Process flow diagram
◆ ◆
P&ID Process & Instrument Diagrams based upon ISA2
◆ ◆ ◆
• Equipment list
◆ ◆
• Instrument index
◆
• Instrument specification data sheet template
◆ ◆
• P&ID Symbols, Legends, Specimen Diagrams, Tag Details
◆ ◆
• Typical loop diagram specimens
◆ ◆
• I/O Schedules
◆ ◆ ◆
• Ring water main
◆ ◆ ◆
• Utility system
◆◆
Equipment specifications, Long lead complete, Preliminary for other Items
◆◆
Pipeline sizing; Complete for major process lines
◆
Piping support and stress analysis
◆ ◆
Site Plan
◆
• Equipment layout plan
◆
• Underground layout drawings
◆
• Safety drawings
◆
• Geotechnical survey & reports
◆
• Material selection guide
◆ ◆
Design pressure / Temperature limits
◆ ◆
Utility summary
◆
Fuel, Chemical, Coolant, Hydraulic & Lubricant Summary
◆ ◆
Startup & 2 year operational spares list
PLANT DESIGN PAGE 2

Description of deliverable P F

◆
Feed material flow control Block diagram
◆
Material handing block diagram
◆
• Product conveyor system. Design layout, flow diverters, densification equipment
specifications. Detailed descriptions, general arrangement drawings, detailed
drawings, equipment specifications
◆
• Product storage area. Detailed descriptions, general arrangement drawings,
detailed drawings, equipment specifications
◆
• Product packaging area. Detailed descriptions, general arrangement drawings,
detailed drawings, equipment specifications
◆
• Silo storage system. Detailed descriptions, general arrangement drawings,
detailed drawings, equipment specification
◆
• Silo homogenization systems. Detailed descriptions, general arrangement
drawings, detailed drawings, equipment specification
◆
• Wieight’ometer, weigh scales etc. Detailed descriptions, general arrangement
drawings, detailed drawings, equipment specifications
◆
• Packaging station. Detailed descriptions, General arrangement drawings, detailed
drawings, equipment specifications
◆
Conveyor, Cranes, Mobile equipment, specifications RFQ etc.
◆
Spares inventory control recommendations
◆
• Consumable spares inventory, storage and tracking systems
◆
• Operational spares inventory, storage and tracking systems
◆
Feeds stock Inventory tracking systems descriptions
◆
Product inventory tracking systems descriptions
◆
Maintenance works shop description, recommendations, tooling requirements
◆
Chemical laboratory requirement lists
◆
• Analytical requirements
◆
• Day to day operational requirements
◆
• Shipping and Q.A. requirements, client support etc.
ELECTRICAL DESIGN BUILDING SYSTEMS

Description of deliverable P F

◆
Area key plans for lighting, tray and grounding layouts
◆
Lighting level calculations
Plant and site lighting layouts
◆
Substation layouts
◆
• Plant distribution center switchgear building and equipment layout
U/G duct bank layout
One-line diagram with interlocks, capacities, voltages. currents, impedances,
◆
• 4.16 kV one-line diagrams
◆
• 600 – 460 V one-line diagrams
• Motor control schematics
• Lighting control schematics
Electrical interface block diagram
◆
Installation details
◆
• Duct bank details
◆
• Lighting and distribution panel schedules
• Tray sizing calculations
◆
• Cable tray general arrangement drawing and detailed drawings
◆
• Cable tray penetration details into buildings
◆
Equipment sizing calculations
◆
Emergency load calculations
◆
System studies, Fault levels, Short circuit current, Minimum/Maximum
◆
Motor start effects, system stability
Transformer tap settings
Motor protection settings
ELECTRICAL DESIGN PLANT SYSTEMS

Description of deliverable P F

Equipment drawings including vendor diagrams

• Front & interior panel layout
• Wiring diagram & terminal layout
• 3-Line diagrams
• Manuals
• Maintenance and instruction manuals
• Electronic equipment manuals, Config data, Data sheets with environmental limits
• Fuse ratings
• Circuit breaker settings
• Battery details including amp-hour ratings
• Relay settings
• Spare parts list
Interconnection diagrams
Cable routing schedules
Schematics
• 4 kV schematics
• 600 – 460 V schematics
• 120 V schematics
• 125 V UPS
• MOV control schematics (Voltage suppression devices)
• Lighting control schematics
• Emergency power schematic diagram
PIPELINE & LAYOUT

Description of deliverable P F

◆
Piping general arrangement
◆
Isometric drawings for N-50 and greater
◆
Isometric drawings for pipework underground

Detailed fabrication drawings for N50 and larger

◆
Piping material specification
◆
Standard piping details
◆
Pipework support calculations
◆
Pipework fabrication and Installation specifications
◆
Pressure test procedure
◆ ◆
Special piping requirements
• Material test certificate
• Welding procedures and inspection certificates (Physical testing reports)
• Inspection reports, certification stamps as required
• Nonconformance, remediation, details and reports
Special piping support details
◆
Stress critical line list
◆
Stress analysis specification
Stress reports, images, etc.
Hydrostatic test diagrams (High pressure pipework)
◆
Details of special requirements, heat tracing, explosion risk requirements, damage
protection requirements, insulation, color coding, plastic pipework requirements etc.
PLANT INFRASTRUCTURE

Description of deliverable P F

◆
Building drawings
◆
Site Details; Drainage, Paving, Fencing
◆
Structural details
◆
Pipe rack supports drawings
◆ ◆
Control systems general requirements
◆
Control systems DCS (Distributed Control System)
◆
PLC (Programmable Logic Controller)
◆
SIS (Safety Instrumented System)
◆
Cable routing diagrams
◆
Electrical equipment list including but not limited to
◆
• Mobile equipment recharging stations design, installation drawings, instructions
◆
• Uninterruptable power supplies design, installation drawings, instructions
◆
• Emergency systems, generators, cooling systems etc. design, installation
drawings, instructions.
◆
Electrical equipment data sheets
◆
Electrical load list, load calculations, cable schedules
◆
Area classification diagrams description

FIRE CONTROL AND PREVENTION

Description of deliverable P F
◆ ◆
Statement of design philosophy
◆
Firefighting equipment layout list & requisitions
Gas and fire detection equipment schedule
Fixed extinguishing systems design
Mobile fire-fighting equipment schedule
Safety equipment schedule
MOTORS, INSTRUMENTATION & CONTROLS

Description of deliverable P F
◆
System block diagram
System functionality definition and interface description between systems
◆
MCC Motor Control Center schedules
◆
• Detailed motor list, type, efficiency, inrush current, operating load range
◆
• Motor data sheets, instructions
◆
• Starter details Direct on line, Star/Delta, Soft start, Variable speed
◆
• Interlock list, fail safes condition list, local disconnect I/D list
System graphic displays
Instrumentation drawings
◆
Instrument cable schedule
Instrument cable routing
Instrument air distribution diagram
◆
Instrument design data and engineering calculations
◆
Instrument power and utility requirements
Alarm & trip schedule
Control room layout
Electrical panel and rack layout drawings
Electrical schematics
◆
• One-line power distribution diagram
◆
• Power distribution schedule
◆
• Grounding diagram for instruments and control systems
• Termination schedule/diagram
• Junction box schedule
◆
• Interconnection diagrams
CIVIL & STRUCTURAL DESIGN

Description of deliverable P F

◆
Civil layouts site plan drawings
◆
Civil design criteria
◆
Road layouts and details

Foundation & concrete structure details

◆
Underground services specification
◆
Underground services layout
◆
Earthworks, excavation procedures, filling & compaction requirements
◆
Earthwork grading drawings
◆
Piling specification
Piling layouts, with support capacities, locations, cutoffs, elevations
◆
Reinforced concrete specification
◆
Structural design criteria
◆
Structural steelwork design and specification
◆
Structural steelwork requisitions
Fireproofing schedule if applicable
Indexed design calculations

ARCHETECTURAL DESIGN

Description of deliverable P F

◆
Building specification
◆
Building layout drawing
Building detail drawings
Schedule of finishes
Schedule of doors and windows
PROCUREMENT

Description of deliverable P F

◆ ◆
Long lead item list
◆ ◆
Approved vendor list
◆
FEED contract deliverable list
◆
Key documents
◆
Material requisitions
◆
Requests for quotation RFQ

CONSTRUCTION

Description of deliverable P F

◆ ◆
Land use plan
◆
Infrastructure strategy document
◆
Temporary facility requirements, requisitions and specifications
• Site huts, toilets, washrooms, and temporary offices
• Mobile and hired equipment, (Man lifts, Cranes, Compressors, fork lift truck etc)
• Communications
• Temporary power, Generators, Electrical hooks-ups etc.
• Scaffolding, staging, protective barriers etc
SCOPE OF WORK

Description of deliverable P F

◆ ◆
Introduction
◆
Management plan
◆
Division of responsibility
◆
Interface systems, Services, etc.
◆
Tie-in details, battery limits, lists, diagrams, drawings

COST ESTIMATE Level 3 (-10% / +15%)

Description of deliverable P F

◆
Estimate report
◆
e-file doc, Proposals for major equipment
e-file doc, Proposals for installation packages
◆
Reference drawing list
◆
Cost estimate and project cash flow forecast
This list is based on the list presented on The Project Definition website. This website usefully
contains descriptions and definitions of the various roles and tasks an engineering contractor is
required to perform under an engineering contract. The list presented here has been amended to
reflect the usual engineering deliverables at the time a new zinc oxide plant project is handed over to
a client. The list assumes building and architectural engineering services are part of the engineering
contract, for an EPCM contract, these services will usually be contracted locally.

In some instances, multiple documentary requirements are covered by a single document for
example an electrical diagram will usually provide;

• Line electrical loads

• Fuse details
• Circuit breaker settings
• Circuit loads and voltages
• Transformer tap settings
• Ground cable requirements
• Interconnection cable details
• Terminal rail details
• Panel Layout, Internal Layout, Spare Parts list.

The documentary requirements are important as they provide a consistent user interface, referenced
using the P&ID numbering schedule. Some of these deliverables are noted as preliminary at the end
of the Engineering contract (Column D) as these data will be continually amended during the course
of a project and during operations.

Translation services have been omitted from the list as translations are usually handled during the
preparation of each document. Translation usually requires the assistance of the client to ensure that
the meaning and intent of the document is properly communicated. It is usual that the client or a
translator approved by the client be tasked separately with translation services. As this is large task
for most plant construction projects, translators play an important role.

Third party data sheets and instructions are not always available in the local language. Under our
normal engineering deliverable requirements, third party information will be provided in the available
language. If a document requires translation it will be handled as an extra service under the terms of
the engineering contract. Where possible local language requirements will be specified in the
purchase contract with a third-party vendor.