GQI-G00G-004 Revision 0 Design Control

Design Control
Bechtel Power Corporation

1.0 PURPOSE

This procedure describes a system for the control and verification of engineering design.
The objective of the system is to ensure that the stipulated design requirements of a
contract are met and that this is achieved as defined in project planning documents.

2.0 SCOPE

This procedure applies primarily to the Engineering Department.

This procedure applies to all projects, including those cases where design is performed
away from the primary work execution center.

This procedure addresses the requirement of ISO 9001, Clause 4.4, “Design Control,” as
defined in the Quality Manual, Section 4.4.

3.0 DEFINITIONS

Bechtel - Bechtel Power Corporation

Project Work Instructions - These documents define the project unique activities,
responsibilities, deliverables, and quality standards necessary to meet the specified
quality requirements of the contract and form part of the Level III Quality System
Documentation.

Department - The split of responsibility of the various functional entities within Bechtel
such as Engineering, Procurement, Construction, Startup, Project Controls, and Project
Administration. See Section 2.4 of the Quality Manual.

Group - The various divisions of expertise required within a Department to perform

tasks. For engineering, groups are also referred to as disciplines. See Section 2.4 of the
Quality Manual.

Chief Engineer - The individual responsible for an engineering group and for ensuring
that the engineering group provides adequate technical resources to support a project.
This includes reviewing and monitoring the quality of technical work, staffing and
monitoring the performance of the group, providing guidance and direction to
Engineering Group Supervisors (as required), and assisting in the resolution of complex
project issues with the customer. The Chief reports to the Manager of Engineering.

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Engineering Manager - The individual assigned to review and monitor the overall
engineering on designated projects and acts as an extension of the office of the Manager
of Engineering. This individual reports to the Manager of Engineering.

Project Engineer (PE) - The individual having responsibility to manage all

engineering/design aspects on a project. This individual reports to the Project Manager
for project-related matters and to an Engineering Manager for administrative and
technical matters.

Engineering Group Supervisor (EGS) - The individual assigned to a project by the Chief
Engineer who is responsible for engineering, design, and control of the Engineering
Group's work. This individual reports to the Project Engineer for project-related matters
and to the cognizant Chief Engineer for administrative and technical matters.

Project Functional Department Manager - The individual (other than a PE) assigned to a
project by the respective Functional Department Manager who is responsible for
managing all aspects of that Department's functions on the project. This individual
reports typically to the Project Manager for project-related matters and to the Functional
Department Manager for administrative matters.

4.0 RESPONSIBILITIES

Functional Department Managers and Chief Engineers are responsible for ensuring that
their staffs are aware of and adhere to the guidelines of this procedure and the documents
referenced within; and work instructions are prepared, issued, and controlled.

Project Managers and Project Functional Department Managers are jointly responsible
for ensuring that the guidelines of this procedure and the documents referenced within it
are adhered to on projects.

Project Engineers are responsible for selecting applicable Engineering Department

Procedures (EDPs); preparing necessary Engineering Department Project Instructions
(EDPIs); collecting all EDPs and EDPIs in a Project Engineering Procedures Manual
(PEPM), as appropriate; and ensuring that the project work instructions for design
control are available to the Project Engineering personnel.

Engineering Group Supervisors are responsible for ensuring that all engineering tasks are
performed in accordance with the EDPs/EDPIs and, as applicable, engineering discipline
manuals.

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5.0 GUIDELINES

5.1 Design and Development Planning

5.1.1 Engineering Planning and Control

All engineering design work is conducted in accordance with an

engineering planning and control program. The program is based on the
scope of work necessary to meet the specified contract requirements.
Guidance for implementation of a project engineering planning and
control program is provided in EDP 3.10 and applicable procedures listed
in Section 6.6.

The project planning documents are broken down into a number of levels
with increasing degree of detail and includes provisions for staffing and
other resources. These documents also address the logs, work schedules,
and reports to be developed and the Engineering Group responsible for
their preparation.

When changes to any level of the planning documents become necessary,

these are evaluated, reviewed, and approved by the same authority levels
that performed the original review and approval.

5.1.2 Project Automation Plan

Requirements for computer programs utilized for engineering design and

analysis and approval of their usage are included in a Project Automation
Plan. If additional computer programs are added to the project after the
initial issue of the Project Automation Plan, these are added to the plan at
the next update.

5.1.3 Design Activities

At the appropriate planning levels, the design activities for each

engineering discipline are identified and the design work is broken down
into manageable tasks or work packages. Within each Engineering
Group, responsibilities for each of the design activities are assigned by the
Engineering Group Supervisor to individuals competent to perform the
work.

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The Project Engineer ensures that the various engineering disciplines or

groups are provided the appropriate resources for completion of the design
in a timely manner.

5.3 Organizational and Technical Interfaces

The control of interfaces that affect Project Engineering work is defined in EDP
4.25. Technical interfaces can occur between:

· Groups within the Engineering Department on a project

· Project personnel and external (non-Bechtel) entities such as the customer,
outside consultants, suppliers, and regulatory bodies
· Project personnel and Bechtel off-project entities such as department or Chief
Engineer staffs
· Engineering Groups and other on-project department personnel

These technical interfaces are included in the Project Engineering planning

process. The external technical interfaces are identified and set forth in the
project planning documents. Internal interfaces either between engineering
groups and other Bechtel entities or intra-project interfaces are identified in
project work instructions.

The necessary information for technical interfaces are documented, reviewed, and
distributed in accordance with project work instructions.

Technical interfaces with the customer are controlled by the Project Engineer.
Interfaces with regulatory bodies such as government agencies, local authorities,
certification authorities, etc., are controlled by the Project Engineer or designated
engineer from the responsible Chief Engineer's Staff.

The Project Procurement Department controls the interface with suppliers in

accordance with the Purchasing Manual - Section 2.0. All technical input is
provided by the responsible Engineering Group(s).

Following subcontract award, with the exception of subcontracts for engineering

and design work only, the interface becomes the responsibility of the Contract
Administrator as discussed in EDP 3DP G06 002. After jobsite mobilization, the
interface is typically the responsibility of the Construction Department.

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Where subcontracts or Technical Service Contracts are awarded for engineering

and design work only as described in EDP 4.57, these are controlled and
administered by the Project Engineer assisted by the cognizant Chief Engineer
and Engineering Group Supervisor.

The Project Quality Services Representative provides assistance with the quality
aspects of the technical interfaces on the project.

Project Administration ensures that documented information is placed into the

project document control center and distributed in accordance with project work
instructions as discussed in GQI-G00G-005, "Document and Data Control." At
the jobsite, design documents are controlled by the Construction Department in
accordance with the procedures listed in Section 6.7.

5.4 Design Input

5.4.1 General

Design input requirements include or are derived from those expressed

directly in the contract and those that result from consideration of the
applicable Bechtel standards, national, international, and local regulations
and the site environmental conditions.

Project design requirements are documented in discipline design criteria

developed in accordance with EDP 4.1. The Engineering Group
Supervisor is responsible for development of a discipline design criteria
document which is coordinated with other affected disciplines for review,
and submitted to the originating discipline's Chief Engineer for review and
approval.

Following approval by the cognizant Chief Engineer, the design criteria

document is approved by the Project Engineer and, as required, submitted
to the customer for review and acceptance.

5.4.2 Customer Requirements

Following review of contract documents, the Project Manager, in

accordance with the Project Manager's Manual and GQI-G00G-003,
"Contract Review," issues the customer's specified design requirements to
the project team through the Project Engineer. During the course of the

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project, the Project Manager distributes any additions or amendments to

the contractual design requirements to the project team through the Project
Engineer.

The Project Engineer ensures that customer design requirements are

reviewed for adequacy. Any requirement found to be inadequate,
incomplete, or that conflict with statutory requirements or Bechtel policy
are brought to the attention of the Project Manager for resolution with the
customer.

5.4.3 Statutory Requirements

The Project Engineer ensures that environmental protection and regulatory

compliance issues are identified, evaluated, and documented by the
cognizant Engineering Groups.

The design criteria documents identify applicable codes and standards and
regulatory requirements including requirements governing safety, public
health, and environmental protection issues.

In the absence of statutory requirements, internationally recognized

standards are used such as ASME, ANSI, IEEE, ISO, etc.

5.4.4 Site Environmental Data

The Project Engineer ensures that the design criteria identifies the site
environmental data applicable to the location of the customer's facilities in
accordance with EDP 3DP G02 010. This data may include
meteorological, geotechnical, and oceanographic data.

The Engineering Groups ensure that the design data resulting from the
environmental conditions are included in the design criteria documents.

5.4.5 Supplier Data

Data received from suppliers and subcontractors is documented,

distributed, and reviewed in accordance with project work instructions.

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Each group affected reviews the supplier document to identify data that
constitute inputs to the project's engineering/design and incorporate as
appropriate such data in the appropriate design output.

5.4.6 Data Exchange

The formal exchange of design data within Engineering Groups and

among project departments is controlled by application of the project's
document distribution system.

To ensure timely flow of technical information among groups, informal

transmittals of information indicating important design developments are
permissible between formal issues of the associated documents.

The effective operation of this system is the responsibility of the

Engineering Group Supervisor, the Project Engineer, the Project
Administrator, and the Project Manager.

5.5 Design Output

5.5.1 General

Design output is documented in accordance with applicable project work

instructions (e.g., EDP 3DP G04 037, Design Calculations; EDP 4.46,
Engineering Drawings; EDP 4.49, Engineering Specifications; EDP 3DP
G06 001, Material Requisitions).

The production and handling of design output documents is controlled by

the Engineering Group Supervisors as described in the project work
instructions.

5.5.2 Meeting Design Input Requirements

Design input data and applicable design criteria are included in design
calculations which form the basis for preparation of specifications,
drawings, and data sheets.

The originator is responsible for incorporating all applicable design inputs

into the design output documents in accordance with project work

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instructions. The appropriate source documents used in the preparation of

design output documents are referenced by the originator.

The design output documents provide complete, unambiguous information

sufficient to define the supply, manufacture, construction work, or service
to be provided, including the applicable quality requirements.

5.5.3 Acceptance Criteria

The originator specifies, as appropriate, in design output documents the

criteria controlling the acceptance or rejection of the material, equipment,
production process, construction work, or service to be provided. The
criteria relate to the required function and performance of the product for
the purpose it is intended to accomplish as defined by the design input
requirements.

5.5.4 Regulatory Requirements

The design output documents conform to appropriate national,

international and local regulations, codes and standards.

5.5.5 Crucial Characteristics

The originator of design calculations, data sheets, and system drawings

includes all characteristics of the design that are necessary for the safe and
effective functioning of the material, equipment, or plant.

These crucial design aspects are defined by the originator in the

specifications and drawings in such a way that they become mandatory
requirements to the supplier or subcontractor or to the Bechtel
Construction Department.

5.6 Design Verification

5.6.1 General

Engineering Group Supervisors ensure that all design work is verified for
accuracy and for confirmation that all design output meet the design input
requirements as defined in Section 5.4 of this procedure.

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Design verification can be performed by a number of methods including

independent checking of design output documents, execution of planned
design reviews, qualification testing, and startup verification.

The requirements for design verification of design work and design output
documents are defined in the project work instructions including, but not
limited to, the following procedures:

· Design Calculations are checked and approved in accordance with

EDP 3DP G04 037.
· Engineering Drawings are checked and approved as required by EDP
4.46.
· Engineering Specifications are checked and approved in accordance
with EDP 4.49 or 4.50, as applicable.
· Material Requisition packages are checked for completeness as
defined in EDP 3DP G06 001.
· Computer programs used for the technical aspects of design are
validated and verified as required by EDP 3DP G04 036.
· Review of supplier or subcontractor design output documents is
conducted in accordance with EDP 4.58.

Systems for documenting design verification are implemented and

maintained by competent personnel assigned to perform design
verification functions.

5.6.2 Independent Check

An independent check of design output documents is performed, as

required, by an individual, other than its author/originator, in accordance
with project work instructions. The individual performing the checking
has adequate qualifications to have originated the document.

This check includes verification that source documents used (i.e., design
data, calculations, etc.) are the latest revision.

Design output documents may also be reviewed by engineering groups

other than the originating engineering group on documents containing
technical interfaces within engineering or between engineering and other
project departments. Checking is conducted in accordance with the
project work instructions.

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Following completion of checking and incorporation of any necessary

amendments, the output documents are reviewed and approved by the
appropriate authorities as detailed in the project work instructions.

Should additional amendments be identified during the review and

approval stage, these amendments are incorporated and the review and
approval process completed.

Document checking can also be performed by off-project technical staff

personnel.

5.6.3 Design Reviews

In addition to independent checking activities, design reviews are

performed, as required, on selected key documents which describe the
design of a particular component, system, or structure. Design reviews
can be accomplished by interdisciplinary design review, independent off-
project review, or project review. Project technical reviews of
engineering design activities are conducted by the cognizant discipline
Chief Engineers in accordance with EDP 4.33. The conduct of off-project
design reviews is performed in accordance with EDP 4.34.

The results of all design reviews, including any corrective actions

stipulated, are documented in accordance with project work instructions.
Records related to design reviews form part of the quality records for the
project and are controlled as described in GQI-G00G-016.

5.6.4 Qualification Testing

Qualification testing may be used as an acceptable method of design

verification in lieu of design review. Testing of material and equipment
provided by suppliers or subcontractors is discussed in GQI-G00G-010,
"Inspection and Testing."

Requirements for qualification testing are specified including the test

method, test configuration, and acceptance criteria. Verification that some
designs or specific design features are adequate and that these designs are
properly integrated can be achieved by suitable qualification testing of a
prototype or initial production unit.

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Qualification tests are witnessed in accordance with specified

requirements and the results recorded.

The results of all qualification tests, including any corrective actions

stipulated, are documented in accordance with project work instructions.

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5.7 Design Changes

5.7.1 General

Design changes may be identified through a number of means including:

· by review of changes to the contract

· as a result of design reviews
· as a result of a testing program
· during a later stage of design development
· during construction
· during plant startup

Identified design changes that could result in the revision of issued

documents or could impact either the project schedule or project cost are
documented, reviewed, evaluated, approved, and resolved. The Project
Manager is responsible for ensuring that a system for controlling changes
is in place.

Field changes to design documents are submitted by Construction to

Engineering as described in the applicable procedures listed in Section
6.7. These changes are handled by Engineering in accordance with EDP
4.62.

Proposed design changes submitted by a supplier are handled by

Engineering in accordance with EDP 4.63.

5.7.2 Implementation

A design change is not implemented until the project work instruction on

controlling changes has been followed and the change approved by the
designated authorities including, if feasible, those responsible for approval
of the original design. The Project Manager and Project Engineer are
responsible for the effective operations of the change control procedure.

The Engineering Group(s) involved implements the approved design

change by revising the affected documents in accordance with the project
work instructions.

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5.7.3 Records

Project personnel receiving revised documents ensure that superseded

documents are stamped superseded and/or removed from the work areas
and working files as described in GQI-G00G-005, "Document and Data
Control."

5.8 Design Validation

Validation that the design work performed by Bechtel conforms to customer

needs and/or requirements is typically carried out in stages by the customer or
during startup.

During construction or installation, the customer may examine the portions built
to verify conformance to the customer's specifications, standards, and other
requirements as defined by the contract.

Performance requirements of the overall design work are validated during the
performance tests. However, certain components, systems, or subsystems may be
operated to validate performance during startup. Problems identified during
startup requiring resolution by Engineering are documented on Startup Field
Reports and handled in accordance with EDP 4.70.

Deficiencies identified during validation of Bechtel's design are documented and

investigated by Bechtel. If the deficiency is confirmed, Bechtel determines and
implements the corrective action(s) required to resolve the deficiency and obtain
customer acceptance, as applicable, of the corrective action. Corrective actions
taken are implemented in accordance with GQI-G00G-014, "Corrective and
Preventive Action."

Correspondence related to deficiencies and corrective actions are documented in

accordance with project work instructions.

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6.0 REFERENCES

6.1 National & International Standards

ISO 9001:1994 (ANSI/ASQC Standard Q9001-1994), "Quality Systems - Model

for Quality Assurance in Design, Development, Production, Installation and
Servicing"

6.2 Management Documents

GQI-G00G-001, "Quality Manual"

6.3 Quality System Procedures

GQI-G00G-003, "Contract Review"

GQI-G00G-005, "Document and Data Control
GQI-G00G-010, "Inspection and Testing
GQI-G00G-016, "Control of Quality Records"

6.4 Engineering Department Procedures (EDPs)

EDP 3DP G02 010, “Environmental Compliance”

EDP 3.10, “Engineering Planning and Control”
EDP 4.1, “Design Criteria”
EDP 4.25, “Design Interface Control”
EDP 4.27, “Design Verification”
EDP 4.33, “Project Reviews”
EDP 4.34, “Off-Project Design Review”
EDP 3DP G04 036, “Standard Computer Programs”
EDP 3DP G04 037, “Design Calculations”
EDP 4.46, “Engineering Drawings”
EDP 4.49, “Engineering Specifications”
EDP 4.50, “ASME III Design Specifications”
EDP 4.57, “Technical Services Contracts”
EDP 4.58, “Supplier Engineering and Quality Verification Documents”
EDP 4.62, “Field Change Request/Field Change Notice”
EDP 4.63, “Supplier Deviation Disposition Request”
EDP 4.70, “Startup Field Report”
EDP 3DP G06 001, “Material Requisitions and Purchase Memorandums”
EDP 3DP G06 002, “Contracts and Subcontracts”

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6.5 Procurement Department Documents

Purchasing Manual - Section 2.0, “Purchase Order Formation”

6.6 Project Controls Department Procedures (PCDPs)

PCDP 40P 00C 502, “Milestone Summary Schedule”

PCDP 40P 00C 503, “Intermediate Schedule for Engineering”
PCDP 40P 00C 507, “Home Office Detailed Schedules”
PCDP 40P 00C 509, “Progress and Performance Curves”
PCDP 40P 00C 511, “Schedule Change Notices”
PCDP Manual, Appendix B (EPPR-100), “Engineering Planning and Control
Program”

6.7 Construction Department Documents

Construction Quality Manual, Procedure 3.1, “Design Document Control”

Field Engineering Manual, Procedure 2.5, “Project Document Control”

Site Managers Manual, Procedure 4.5, “Quality Requirements”

6.8 Office Services - Administration and Project Services Documents

Gaithersburg Project Administration Procedures (GPAPs)

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