DIVISION ENGINEERING

&
CONSTRUCTION

DESIGN PHILOSOPHY
 CONTENTS
1. INTRODUCTION 4
1.1. Foreword 4
1.2. Objectives 4
1.3. Scope 4
2. ABBREVIATIONS & DEFINITIONS 5
2.1. Abbreviations 5
2.2. Definitions 9
3. APPLICABLE STANDARDS 14
4. KEY OPERATIONAL REQUIREMENTS 15
4.1. Functionality 15
4.2. Maintainability 15
4.3. Health, Safety and Environmental 15
4.4. Layout 15
4.5. Robustness 15
4.6. Redundancy 16
4.7. Flexibility 16
4.8. Reliability 16
4.9. Control & Monitoring 16
4.10. Turndown 16
4.11. Documentation 17
5. DESIGN CONSIDERATIONS 18
5.1. General 18
5.2. Capacity 18
5.3. Configuration 19
5.4. Staged Development 19
5.5. Environment Considerations 19
5.6. Operations Input 20
6. REVIEW AND VERIFICATION OF CONCEPTUAL DESIGN 21
7. DESIGN AND ENGINEERING 22
7.1. General 22
7.2. Process 23
7.3. Mechanical 24
7.4. Piping and Layout 25
7.5. Electrical 26
7.6. Control and Instrumentation 28
7.7. Telecommunications 30
7.8. Health, Safety and Environmental 30
7.9. Civil/Structural 31
7.10. Architectural 32
8. PROJECT ORGANISATION 33
9. VENDOR SELECTION 33
10. TAGGING AND LABELLING 33
11. DOCUMENTATION 34
11.1. General 34
11.2. Process Flow Diagrams 35
11.3. P&IDs 35
11.4. Safety Device Register 36
11.5. Safeguarding Diagrams 36
11.6. Alarm and Trip Schedule 36
DESIGN PHILOSOPHY Page 2
 11.7. Controller Tuning Parameters Register 36
11.8. Cause and Effect Charts 36
11.9. Vessel Level Co-ordination Diagrams 37
11.10. Hazardous Area Drawings 37
11.11. Instrument Layout Drawings 37
11.12. Valve Registers 37
11.13. Data Sheets 37
11.14. Special Piping Items Databook 38
11.15. Vendor Documentation 38
11.16. Fiscal Metering Dossier 38

DESIGN PHILOSOPHY Page 3

1. INTRODUCTION

1.1. Foreword

This document represents the Sonatrach (SH) Operational Philosophy

on overall design requirements for projects in Algeria.

1.2. Objectives

The primary objective of this document is to provide guidance to

discipline engineers in progressing a conceptual design through to
detailed design, based on operational requirements.

1.3. Scope

The philosophy requirements apply to oil, gas and condensate

development.

This document is a compilation of general requirements that would

have appeared in various other requirements. All general requirements
are documented here in order to remove duplication.

DESIGN PHILOSOPHY Page 4

2. ABBREVIATIONS & DEFINITIONS

2.1. Abbreviations

Algerian Algerian State Telecommunication Department

PTT
A.C. Alternating Current
A/D Analogue to Digital (signal conditioning)
AFC Approved For Construction
ALARP As Low As Reasonably Practicable
API American Petroleum Institute
ASTM American Society for Testing and Materials
BD Bursting Disc
BDV Blowdown Valve
BEP Best Efficiency Point
BMS Burner Management System
BS&W Base Sediment and Water
BTX Benzene Toluene Xylene
CBA Cost Benefit Analysis
CCR Central Control Room
CCS Combustion Control System
CCTV Closed Circuit Television
CE Certification European
CENELEC Comite Européen de Normalisation Electrotechnique
CFD Computational Fluid Dynamics
CITHP Closed In Tubing Head Pressure
COSHH Control of Substances Hazardous to Health
CPF Central Processing Facility
CPU Central Processing Unit (computers)
CRA Corrosion Resistant Alloy
CRC Central Control Room
D.C. Direct Current
D/A Digital to Analogue (signal conditioning)
DCS Distributed Control System
DLE Dry Low Emissions
DP Differential Pressure
EDP Emergency Depressurisation System
EDPV Emergency Depressurisation Valve
EPRIB Emergency Position Radio Indication Beacon
ESD Emergency Shutdown Systems
ESDV Emergency Shut Down Valve
ESP Electro-Submersible Pump
F&G Fire and Gas
FAT Factory Acceptance Testing
FGS Field Gathering Stations
FMEA Failure Mode & Effect Analysis
FMECA Failure Mode, Effect & Cause Analysis
FRA Fire Risk Analysis
FSD Full Scale Deflection
Fv Volumetric flow rate at any given time
GA General Alarm
SH Sonatrach
DESIGN PHILOSOPHY Page 5
 GIN Gas Index Number =LCV/SG0.5
GRP Glass Reinforced Plastic
H2S Hydrogen Sulphide
HAZID Hazard Identification
HAZOP Hazard and Operability
HF High Frequency
HIPP High Integrity Pressure Protection
HIPPS High Integrity Process Protection System
HMI Human Machine Interface
HP High Pressure
HP/LP High Pressure / Low Pressure
HSE Health Safety and Environmental
HVAC Heating, ventilating & Air Conditioning
HVOF High Velocity Oxygen Flame
I.T. Information Technology
ITU International Telecommunication Union
I/O Input/Output
I+PD Advanced Controller Algorithm
IEC International Electro technical Commission
IPF Instrumented Protective Function
ISO International Standards Organisation
ItoP Current to Pneumatic Converter
ITU International Telecommunication Union
JTV Joule Thompson Valve
LACT Lease Automatic Custody Transfer
LAN Local Area Network
LCC Local Control Centre (normally in a remote location)
LCF Low Cycle Fatigue
LCV Level Control Valve
LP Low Pressure
LPG Liquefied Petroleum Gas
LSA Low Specific Activity
LTI Lost Time Incident
mA Milliamp
MAC’s Manual Alarm Call Points
MCB Main Control Building
MCB Miniature Circuit Breaker
MCC Motor Control Centre
MDF Main Distribution Frame
mm Millimetre
MOL Main Oil Line
MSDS Material Safety Data Sheet
MTBF Mean Time Between Failure
MTO Material Take Off
MTTR Mean Time To Repair
mV Milli Volt
NAS National Aerospace Standard
NFPA National Fire Protection Association
NGL Natural Gas Liquid
NPS Nominal Pipe Size
NPSH Net Positive Suction Head
NPSHA Net Positive Suction Head Available
DESIGN PHILOSOPHY Page 6
 NPSHR Net Positive Suction Head Required
NRV Non Return Valve (Check Valve)
OD Outside Diameter
OEM Original Equipment Manufacturer
P&ID Piping & Instrumentation Diagram
PA Public Address
PABX Private Automatic Branch Exchange
PCHE Printed Circuit Heat Exchanger
PDCS Power Distribution Control System
PEFS Process engineering flow schemes (diagrams)
PFD Process Flow Diagram
PG Pressure Gauge
PID Proportional Integral Derivative (3 term controller algorithm)
PLC Programmable Logic Controller
ppm Parts per million
PSD Process Shut Down
PSDV Process Shut Down Valve
PSV Pressure Safety Valve
PTS Process Trip Systems
PTT Algerian State Telecommunication Department
PWHT Post Weld Heat Treatment
QRA Quantitative Risk Assessment
RBD Reliability Block Diagram
RCM Reliability Centred Maintenance
RCS Reliability Centred Spares
RF Radio Frequency
RFQ Request For Quotation
RIO Remote Input / Output
RO Restriction Orifice
RPM Revolutions Per Minute
RTD Resistive Temperature Device
RTJ Ring Type Joint
RV Relief Valve
RVP Reid Vapour Pressure
SAFE Safety Analysis Function Analysis (Cause & Effect) Chart
SAS Safety Automation Systems
SCADA Supervisory Control And Data Acquisition
SDV Shutdown Valve
SER Sequence of Events Recorder
SF6 Sulphur Hexafluoride (Gas insulator for switchgear)
SG Specific Gravity
SI System International
SIL Safety Integrity Level
TER Telecommunication Equipment Room
TI Temperature Indicator
TMS Telecommunication Monitoring Surveillance
TVP True Vapour Pressure
UCP Unit Control Panel
UHF Ultra High Frequency
UPS Uninterruptible Power System
VDU Visual Display Unit (monitor)
VHF Very High Frequency
DESIGN PHILOSOPHY Page 7
 VSAT Very Small Aperture Terminal
VSD Variable Speed Drive
WAN Wide Area Network
WHRU Waste Heat Recovery Unit

DESIGN PHILOSOPHY Page 8

 2.2. Definitions

General
Can Can requirements are conditional and indicates a
possibility open to the user of the philosophy.

Commissioning Commissioning refers to the preparation for/and

introduction of process fluids for the first time.

Consider Is a course of action that must be documented to

Considered demonstrate the philosophy requirement has been
Consideration addressed with a clear recommendation that is subject to
Company approval.

May May indicates a course of action that is permissible

within the limits of the philosophy (a permission).

Shall Shall is an absolute requirement which shall be followed

strictly in order to conform with the philosophy.

Should Should is a recommendation. Alternative solutions

having the same functionality and quality are acceptable.

Start-up Start-up refers to the restart of any equipment following

planned or unplanned shutdown.

Technical
Criticality Criticality is a relative measure of the consequence of a
particular failure mode and its frequency of occurrence.
The criticality value is used to rank failure modes when
performing an FMEA

Emergency This is the automatic (or manual) shutting down of a

Shutdown (ESD) process train or complete production facilities. This will
normally be used in the event of a recognised
emergency.

Failure The termination of the ability of an item to perform its

required function. Failures may be unannounced and not
detected until the net test or demand, or they may be
announced and detected at the instant of occurrence.

Failure Mode Critical Failure: A failure which is both sudden and

Types causes cessation of one or more fundamental functions.
Note: This failure requires immediate corrective action in
order to return the item to a satisfactory condition.

Degraded Failure: A failure which is gradual, partial, or

both.
Note: Such a failure does not cease the fundamental
functions, but compromises one or several functions.
DESIGN PHILOSOPHY Page 9
 The function may be compromised by any combination of
reduced, increased, or erratic outputs. In time, such a
failure may develop into a critical failure.

Incipient Failure: An imperfection in the state or

condition of an item or equipment so that a degraded or
critical failure can be expected to result if corrective
action is not taken.

Failure Rate: The rate at which failures occur as a function of time or

as a function of demands.
Note: In some definitions the failure rate is expressed as
the expected number of failures of a given failure mode,
per item, in a given time interval (calendar or operational
time), or as the expected number of failures of a given
failure mode, per item, in a given number of operations.
These interpretations of the definition imply the
assumption that the failure rate is constant, i.e.
independent of time. The failure rate is expressed as
failures per million item hours or per million demands.

FMEA – Failure Stands for Failure Mode and Effects Analysis. A FMEA
Mode and is an inductive, bottoms-up method of analysing system
Effects Analysis design and performance. The core of the analysis is the
determination of the effects of various types of failures on
a system.

FMECA - Failure Stands for Failure Mode, Effects, and Criticality Analysis.
Mode, Effects, A FMEA is an inductive bottoms-up method of analysing
and Criticality system design and performance. The core f the analysis
Analysis is the determination of the effects of various types of
failures on a system. A criticality factor, assigned to each
failure mode, allows ranking the most severe failure
modes and the ones most likely to occur. The analyst
may then target these failure modes in order to reduce
their probability of occurrence.

Hazard The potential for damage to people, processing facilities

and the environment.

Health Refers to occupational health only.

I+PD Proportional and derivative action on change of PV, not

on error.

Instrumented A system normally made up of sensor(s), logic and a final

Protective control element(s) (ESDV) installed to prevent a
Function hazard(s).

MIL-HDBK-217 MIL-HDBK-217 is a reliability prediction standard which

(217) MTBF includes mathematical reliability models for nearly all
DESIGN PHILOSOPHY Page 10
 Calculations types of electrical and electronic components based on
parameters of the components such as number of pins,
number of transistors, power dissipation, and
environmental factors. Results from MIL-HDBK-217 are
provided as both a failure rate and as an MTBF (Mean
Time Between Failures) where the MTBF is the
mathematical inverse of the failure rate.

Monte Carlo A complex RBD runs Monte Carlo Simulations on

systems during its calculation. A Monte Carlo Simulation
will perform random tests on the specified system in
order to provide an analysis of the overall Reliability and
Availability of the system. The result of these simulations
will determine the Reliability and Availability of the RBD.

MTBF – Mean Mean Time Between Failures is the mean time expected
Time Between between failures and is measured in hours. It is a
Failures statistical value and is meant to be the mean over a long
period of time and large number of units. For constant
failure rate systems, MTBF is the inverse of the failure
rate. (Technically MTBF should be used only in reference
to repairable items, while MTTF should be used for non-
repairable items, but MTBF is commonly used for both
repairable and non-repairable items).

MTTF – Mean Mean Time to Failure is the mean time expected to the
Time to Failure first failure of a piece of equipment. It is a statistical
value and is meant to be the mean over a long period of
time and large number of units. For constant failure rate
systems, MTTF is the inverse of the failure rate.
(Technically MTBF should be used only in reference to
repairable items, while MTT should be used for non-
repairable items, but MTBF is commonly used for both
repairable and non-repairable items.)

MTTR - Mean MTTR, or Mean Time to Repair, is defined to be total

Time to Repair amount of time spent performing all corrective
maintenance repairs divided by the total number of those
repairs.

Number of The total number of times an item is called upon to

Demands become effective during the period of the event data
surveillance.
Note: On the data forms the number of demands is
given for the total population.

Operational Time The period of time during which an active item performs
its intended function, i.e. the accumulated time in service
during the period of the event data surveillance.
Note: On the data forms the operational time is specified
as the accumulated time in active operation for all items
in the population of interest.
DESIGN PHILOSOPHY Page 11
 PI+D Derivative action on change of PV, not on error.

Process This is the automatic isolation of an individual process

Shutdown unit(s) or operating equipment caused by an abnormal
(PSD) process operating condition.

Process Trip This is the initiation of a valve(s) (open, closed or

minimum stop) to reduce the risk of an abnormal
operating condition occurring.

RBD – Reliability A Reliability Block Diagram (RBD) is a way of

Block Diagram representing a system that contains redundancy in its
elements. Redundancy is used for mission critical
functions where a single-point failure is not acceptable
and reliability needs to be improved. Generally
represented in a graphical manner, a simple RBD may
be calculated using analytical solutions, while a more
complex RBD may be calculated using a Monte Carlo
simulation. Results may include reliability, availability
failure rate, and MTBF.
RCM – Reliability RCM, Reliability Centred Maintenance, is a methodology
Centred used to define a maintenance program while having
Maintenance reliability as an input to the decision making process.

Reasonably As Low As Reasonably Practicable. The use of latest

Practicable guidelines and technology to minimise hazards without
excessive cost. Cost benefit analysis and quantitative
risk assessment shall be carried out to demonstrate this.

Redundancy Redundancy is the existence of more than one piece of

equipment, any of which could perform a given function.
These multiple pieces of equipment are used to help
improve the reliability and availability of the system.
Redundancy is generally expressed as the number of
pieces of equipment required and the total number
available.

Reliability Reliability is defined to be the ability of an item to perform

a required function under stated conditions for a stated
period of time. The numerical value of reliability is
expressed as a probability from 0 to 1 and is also
sometimes known as the probability of mission success.
Reliability is the probability, assuming the system was
operating at time zero, that continues to operate until
time t.

Reliability A rational method for determining the stocks of spare

Centred Spares parts needed. Uses the output from RCM analysis to
determine the spares needed to support the RCM
maintenance decisions.

DESIGN PHILOSOPHY Page 12

 Repair Time Repair time is recorded in terms of manhours and active
repair time.
Manhours are the total number of manhours spent on the
repair operation. Active repair time is the average time
required to analyse the failure, repair and return the item
to a state of readiness.
Note: This excludes the time to detect the failure, time to
isolate the equipment from the process before repair,
delay and waiting for spare parts of tools, and any time
after the repair has been completed even if the item is
not put into service immediately. Time for testing is,
however, included when this is necessary because of the
failure or the repair operation.

Revealed Failure A failure whose occurrence is inherently apparent (i.e.

results in an alarm or process trip)

Risk The combination of the probability of an undesirable

event occurring and the most likely consequence of the
event.

Risk Priority Used in FMEA analysis to rank the importance of

Number (RPN) different types of failure. RPN = Severity x Occurrence x
Detection.

System Integrity The ability of the system to perform the required safety
function under all operating conditions and within the
required time scale.

Uninterruptible A facility to provide continuous ‘no break’ electrical power

Power Supply supply to vital services. The supply can be either a.c. or
d.c. or both.

Unrevealed A failure that is dormant in a Safeguarding system. The

Failure failure is normally revealed when either the system is
required to work and fails (partly or totally) to function or
when the system is tested.

DESIGN PHILOSOPHY Page 13

3. APPLICABLE STANDARDS

Any equipment or systems installed shall comply with the relevant Standards,
Specifications, Industry Codes, Algerian Laws and Sonatrach Standards:

 Algerian Legislation

 Sonatrach Standards

 International Codes and Standards

 Algerian Codes and Standards

 Industry Codes and Standards

Journal Official de la Republique Fransaise, ‘Usines De Traitement Au Petrole

Brut, de ses Derives et Residues Amenagement et Exploitation’ should be
used for reference.

DESIGN PHILOSOPHY Page 14

4. KEY OPERATIONAL REQUIREMENTS

The SH Operational Philosophies have been produced to ensure that the

development of oil, gas and condensate facilities satisfactorily address Key
Operational Requirements from design, engineering, and installation through
to commissioning.

The following Key Operational Requirements were used to develop the

philosophy requirements.

4.1. Functionality

4.1.1 All installed facilities shall be capable of working as designed both as

an individual component or sub-system and also as part of a complete
operating system.

4.2. Maintainability

4.2.1 All equipment shall be designed and facilities provided such that
maintenance can be carried out safely, quickly and easily with
minimum disruption to production.

4.2.2 Equipment selection and design shall be carried out to maximise

operational up-time, minimise maintenance and life cycle costs.

4.3. Health, Safety and Environmental

4.3.1 All installed facilities shall comply with SH’s HSE requirements.

4.3.2 The design shall take into consideration risks to personnel during
routine and non-routine operations and maintenance activities.

4.3.3 The design shall document the methodology for shutting down,
depressuring, draining, purging and isolating all items of equipment. A
nitrogen connection shall be provided to pressure test the equipment
once isolated.

4.4. Layout

4.4.1 Equipment layout shall ensure safe access for routine operation,
equipment monitoring and maintenance activities. It shall be designed
to minimise hazards to personnel and other equipment in emergency
situations, as well as providing some shelter from direct sunlight during
routine operation.

4.5. Robustness

4.5.1 Equipment functionality shall be robust to typical variations in process

conditions, environmental condition, product specifications, feed
composition, and sand production. It shall also be designed to enable
operations to continue production with loss, damage, maintenance, or
reduced performance of equipment.

DESIGN PHILOSOPHY Page 15

 4.5.2 Systems should be designed to degrade gracefully. This means that a
minor failure should result in a corresponding loss of functionality.
Where possible the operator should be alerted to the situation.
However, a minor failure should not result in production being stopped
or reduced.

4.6. Redundancy

4.6.1 The facilities shall be designed to minimise the effect on total

production caused by the shutdown of individual items of equipment.
There shall be sufficient sparing, capacity and flexibility to maintain
annual production targets.

4.6.2 The design and selection of equipment shall enable the minimum
number, type and variety of spare parts to be held on site. Equipment
and spares shall be selected to minimise life cycle costs.

4.7. Flexibility

4.7.1 Sufficient isolation, control and monitoring shall be available to change

process/utility routing where parallel equipment or multiple trains are
installed.

4.7.2 The total capacity of the storage tanks should be between three and
seven days of full production, to be determined during detailed design
based on export requirements.

4.8. Reliability

4.8.1 Equipment selection and design shall ensure high availability and
reliability. Proven design and technology shall be selected for the duty
and location.

4.8.2 Remote location of the facility in the Algerian desert shall be taken into
consideration when selecting equipment. Maintenance costs can be
excessive due to the logistics associated with obtaining spares and
vendor support. Life cycle costs shall be used to select equipment not
just capital cost.

4.9. Control & Monitoring

4.9.1 In general all equipment shall be capable of being monitored and

controlled from a central control point i.e. the CCR.

4.9.2 In remote sites comprehensive local control facilities shall be provided.

These should be linked via communications to the central control room
from where the operator can monitor and exercise limited control over
the facilities.

4.10. Turndown

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 4.10.1 The design shall enable the process to be adequately operated and
controlled at the required turndown achieving product specification
without compromising equipment operation, safety and environment.

4.11. Documentation

4.11.1 All installed equipment shall be supplied with comprehensive

documentation clearly showing the equipment detail, design intent,
operating procedures, emergency procedures, maintenance
requirements, etc.

4.11.2 The design is to include for the development and documentation of

start-up and commissioning procedures.

4.11.3 Vendor documentation shall be of the same standard as all project

documentation.

DESIGN PHILOSOPHY Page 17

5. DESIGN CONSIDERATIONS

5.1. General

5.1.1 The equipment shall be capable of achieving the product specifications

and recovery rates over the full range of compositional variation,
ambient conditions, at minimum and maximum design rates.

5.1.2 The facility shall be capable of operating continuously with minimal

operator intervention and without the need for overrides on protective
equipment.

5.1.3 The facility components shall be of proven design for the intended duty.

5.2. Capacity

5.2.1 In the design and sizing of the facility a complete set of data on the
predicted variations in the inlet/wellstream quantities, composition and
characteristics shall be considered. Simulation data should be
available to cover all known operating cases over the lifetime of the
field. From the simulation results, sizing cases shall be tabulated for
each equipment item.

5.2.2 The design case (maximum and minimum) shall be determined for all
processes and equipment. In selecting the sizing of all equipment and
pipework the following shall be addressed:

 Maximum and minimum total liquids rate case.

 Maximum and minimum crude oil/condensate rate case.
 Maximum and minimum water rate case.
 Maximum and minimum gas rate case.
 System start-up.
 Different Operating Modes and Configurations.
5.2.3 The maximum capacity of the facility shall include the following
requirements as stated in the Basis of Design:

 Design capacity.
 Design margin over and above the required design capacity.
 Additional capacity to rerun of off-spec fluids at the required rate.
 Additional capacity to make up for plant unavailability.
5.2.4 Control valves should be designed such that the maximum flowrate is
achievable. However for start-up and early production, undersized
control valves maybe required. The undersized control valve should be
fitted for start-up. Where ever practical it should be possible to fit larger
internals in a control valve to meet the maximum duty. If this turndown
is too great for one size of body then two valves should be installed.

DESIGN PHILOSOPHY Page 18

 5.2.5 Similarly for start-ups and early production some control valves will
require to work at their maximum capacity. This will greatly reduce
over field life. It should be possible to fit reduced size trims in these
control valves.

5.3. Configuration

5.3.1 The system configuration should be established based on optimisation

with respect to:

 Minimise environmental emissions.

 Minimise heating, cooling and recompression requirements.
 Avoidance of special design requirements.
 Minimise life cycle costs (CAPEX and OPEX).
5.4. Staged Development

5.4.1 Where a field is to be developed in stages consideration shall be given

to full field development requirements during the design of the first
stage. Areas that require particular attention include:

 Layout of plant, utilities and support facilities. Layout for 1 st

stage development shall take in to consideration future layout
requirements.

 Utility requirements. Common utility requirements shall take into

consideration requirements for full field development. The
design should include redundancy for future requirements or the
ability to add extra capacity without excessive cost or
modification.

 Support infrastructure requirements, (base camp, sewage

treatment, waste disposal, telecommunications, transportation,
etc.). The support infrastructure shall take into consideration the
maximum requirements for normal operation.

 The CCR shall be big enough to accommodate full field

development, this includes capacity for personnel and
equipment.

 Emergency facilities such as fire fighting equipment shall be

easily added to or be sufficiently sized for future requirements.

 Provision of tie-in facilities (e.g. flanges, valves) to minimise

future downtime and construction effort.

5.5. Environment Considerations

5.5.1 The equipment needs to be able to work satisfactorily in desert

conditions, i.e. ambient temperatures of 55 deg C (shade) and with
possible continuous exposure to direct sun, plus the possibility of
windblown dust and sand. During night-time in winter, temperatures

DESIGN PHILOSOPHY Page 19

 can drop below 0 Deg C. There is also the possibility of occasional
heavy rain showers during winter months.

5.5.2 All equipment shall be robust and demonstrate reliable operation in

similar conditions.

5.5.3 Consideration shall be given to operational instability due to ambient

temperature changes.

5.5.4 Adequate shielding and shelter from the sun shall be provided for all
electronic equipment and equipment sensitive to high temperature.
Exposed field equipment could be subjected to high levels of direct
sunlight with high surface and equipment operating temperatures (circa
95 Deg C).

5.5.5 Adequate shielding and shelter from the sun shall be provided for
personnel required to work for long periods outside.

5.6. Operations Input

5.6.1 Operations input and review shall be sought throughout the project life
cycle from Design through to Commissioning. Operations should be
involved in the project as early as possible.

5.6.2 Operations input and review shall be sought for the following as a
minimum before finalising:

 Process selection and detailed design.

 PFDs and P&IDs
 Layout including 3D models
 Control philosophy
 Shut down philosophy
 Communication systems philosophy
 Start-up and commissioning procedures
 Operating procedures
 Emergency response procedures
 HAZOPs and HAZANs
 Design Reviews

DESIGN PHILOSOPHY Page 20

6. REVIEW AND VERIFICATION OF CONCEPTUAL DESIGN

6.1 Prior to commencing detailed design a full review and verification of the
conceptual design shall be carried out. The engineer shall familiarise
himself with any existing facilities, site details, Operational
Philosophies, Conceptual Design and Basis of Design. Any
inconsistencies shall be clarified and any additional information
obtained. A Conceptual Design Verification Report shall be prepared.

6.2 The conceptual design documents are not an absolute reference but
are to be used with caution and intelligence. Optimisation of the
concept with respect to the key operational requirements should be
considered and any changes approved by SH.

6.3 Technical notes and Conceptual Design Reports are presented as

information. The Design Engineer shall not use these as a substitute
for carrying out detailed review and calculations.

6.4 The process and utility design philosophies shall be updated in

accordance with the overall design development, specifications, codes,
standards and procedures.

DESIGN PHILOSOPHY Page 21

7. DESIGN AND ENGINEERING

7.1. General

7.1.1 The design and engineering phase shall include:

 Complete survey of existing terrain to determine layout, design

and engineering for all facilities.
 Production of Approved for Construction (AFC) drawings and
documents. AFC shall not be permitted on any documents or
drawings with ‘holds’ on them without SH approval.
 Key documents, drawings, specifications or data sheets shall not
be issued prior to completion of inter-disciplinary review.
 Complete all equipment and material requisition documents for
enquiry and purchase.
 Review and approve vendor drawings and documents. Vendor
drawings and documents shall conform to SH Operational
Requirements in terms of format, detail and presentation.
 Prepare all test procedures for civil, mechanical, electrical and
instrumentation.
 Prepare commissioning procedures.
 Prepare operating manuals.
 Produce design specifications and construction specifications
 Produce all required drawings, data sheets, specifications,
reports, studies, MTO’s, requisitions, spares list, etc.
 Participation in and execute multi-discipline activities such as
Safety Audits/Reviews, Environmental Audits/Reviews, Quality
Assurance Audits, Design Reviews, etc.
 Execution of an initial coarse HAZOP and a detailed HAZOP at a
suitable point in the design design. A pre start-up HAZOP shall
also be carried out.
 Confirmation, in the form of a written report, that the integrity of
safety features in the conceptual design, HSE philosophy or
HSE requirements in any specific operational philosophy have
not been compromised by any design or design modification.
 Preparation of studies, reviews, documentation, etc. to
demonstrate that all issues relating to HSE, reliability, efficiency,
maintainability and constructability have been adequately
addressed.
 Incorporation of the Sonatrach system and procedures, for
tagged items and spares listings.
7.1.2 All calculations produced to substantiate the design shall be legible and
in a consistent format. All computer hardware and software, including
specially developed spreadsheets, shall be checked and verified prior

DESIGN PHILOSOPHY Page 22

 to use. The calculations for all disciplines shall be collated and indexed
for handover to SH.

7.1.3 All design calculations, specifications, drawings and all other related
documents shall be performed using SI units.

7.2. Process

7.2.1 The process engineering scope for the design shall include but not be
limited to the following:

 Review and verification of conceptual study data, reports and

studies.
 Check and optimise the heat and material balance, process
selection, process configuration and equipment sizing.
 Perform additional studies and calculations to confirm and verify
the process design and equipment-sizing basis, including the
operability of the process control system.
 Perform hazard assessment studies, and confirm the level of
safety provision for shutdown to prevent downtime and
excessive flare loadings.
 Update process and utilities design philosophies in accordance
with overall design development and Vendor data.
 Update process and utility flow diagrams and generate new
diagrams as necessary.
 Generate utility load tables.
 Generate P&ID’s to include information resulting from the
detailed design as it develops (i.e. addition of Vendor
information, line breaks, etc), and to provide issues up to AFC.
Maintain and control P&ID masters.
 Prepare HSE documents as required, including a hazardous
product schedule to support the preparation for, and execution
of, HSE reviews. Take part in HSE reviews and audits.
 Prepare and update equipment data sheets.
 Prepare and update equipment list to include latest sizing, skid
weight and process data. Ensure principal disciplines are co-
ordinated to be aware of latest equipment list contents.
 Prepare and update line list including such information as line
number, service, minimum/normal/maximum design parameters
etc. for all process and utility lines.
 Prepare and update cause and effect charts.
 Provide input to preparation of start-up and operating manuals.
 Prepare and update process safeguarding flow schemes
identifying the isolation valves (shut off valves, ESD’s) blow
down provisions and design pressure profile.
 Implement recommendations arising from safety reviews.
DESIGN PHILOSOPHY Page 23
  Provide input to a detailed HAZOP review of the whole design
(including Vendor Packages) before conclusion of the detailed
design phases.
 Carry out Detail Design review and implementation of
recommendations found critical to project requirements.
 Prepare a waste management review of the plant to look at ways
to minimise/eliminate hydrocarbon/liquid emissions.
 Participate in the review of other discipline documents.
7.3. Mechanical

7.3.1 The mechanical engineering scope for the design shall include but not
be limited to the following:

 Review and verification of conceptual study data, reports and

studies.
 Integration of the equipment into an overall facility design,
including the interface with both offsites and onsite facilities, and
which meets with requisite criteria during all phases of operation.
 Preparation of all standalone multi-discipline technical
specifications for mechanical equipment and packages.
 Preparation of mechanical data sheets and enquiry/purchase
requisitions for all equipment including but not limited to, vessels,
heat exchangers, pumps, skid packages and mechanical
equipment.
 Assist in evaluation of bids, recommendations for purchase,
liaison with Vendors, review and approval of Vendor data and
participation in Vendor inspection and testing of equipment and
packages, as required.
 An Availability and Reliability Review to demonstrate design
plant availability shall be carried out.
 A Mechanical Handling Review including requirements for
access and lifting arrangements to enable effective operations
and maintenance suitable for the location.
 A Maintenance Review to demonstrate items of equipment can
be isolated and maintained with minimal effect on adjacent
equipment shall be provide.
 An Equipment Suitability Review based on purchase requisitions
ensuring that operation and performance of the equipment has
not been adversely affected by changes in design data (e.g.
process revisions or finalisation of pipe routings) shall be
provided.
 A Noise and Vibration Review defining noise and vibration levels
across the Plant and requirements for noise attenuation, having
protection and access restrictions shall be provided.
 Produce a complete spares schedule for commissioning and
several years operation (the number of years will be defined in
DESIGN PHILOSOPHY Page 24
 the Basis of Design). This shall comprise a tabulation of Vendor
recommended spares.
 Maintain list and produce studies/documentation (corrosion and
erosion studies) to demonstrate that the material selections are
suitable for the required conditions. This shall include gasket,
seal materials (e.g. door seals).
 Prepare installation and commissioning procedures.
 Attendance at vendor site for witness testing.
 Prepare piping specifications.
7.4. Piping and Layout

7.4.1 The piping and layout scope for the design shall include but not be
limited to the following:

 Review and verification of conceptual study data, reports and

studies.
 Update site plan and plot plant.
 Prepare piping studies to optimise major pipe routes so that
hydrocarbon inventory in the Plant is minimised.
 A fully detailed piping/layout design for all process and utility
systems shall be produced.
 Prepare a list of piping special (SP) items including special
materials.
 Produce complete equipment layouts for the plant. Show and
identify all main equipment locations and outlines including major
piping and cable routing.
 Produce a 3D piping model to indicate general arrangement for
all systems. Isometrics will be produced to show elevations and
cross sections to fully define routing and location of piping,
showing location of pipe racks, equipment, in-line equipment and
instrument locates, pipe support positions, their arrangement
and type for all piping 2” NB and above.
 Produce a complete set of piping isometrics for all piping other
than small diameter minor services (generally 1½” and below).
ISO-Sheet should include a full material take-off (MTO) for each
drawing. The piping line list shall include hydrostatic test
requirements, stress relief limits, field welds and insulation
thickness. All welded attachment pipe supports shall be shown.
 Confirm isometrics are consistent with P&IDS.
 Produce system isometrics as required by process engineers,
e.g. flare system.
 Produce fully developed standard pipe support specifications
with standard pipe support drawings.

DESIGN PHILOSOPHY Page 25

  Provide specifications and drawings for non-standard pipe
supports including special applications such as gas compressor
piping supports, etc.
 Provide and issue through detailed design material take-offs.
Material take-offs shall be continuously kept up to date.
 Provide stress analysis of all piping systems, co-ordinate with
Vendors stress analysis of critical lines to/from packages.
 Evaluation of bids for piping valves, pipefittings and special
items.
 Review and approval of Vendor documentation.
 Provide all necessary fabrication/construction/testing
specifications and procedures for piping, including welding
specifications, along with all necessary procedures.
7.4.2 Plot Plans and Drawings

 The unit plot plan should be drawn so that North reads in the
same direction on the paper as the main plant reference
drawings.
 Establish specific control points such as main columns and
locate these by coordinates, and then dimension all equipment in
the group from these columns.
 Each plan must clearly indicate its top and bottom elevation
limitations.
 All plans should be labelled in a similar manner for clarity and
uniformity.
7.5. Electrical

7.5.1 The electrical engineering scope for the design shall include but not be
limited to the following:

 Review and verification of conceptual study data, reports and

studies.
 Develop and finalise all aspects of the electrical design.
 Update the load schedule using information from other
disciplines.
 Update utility load tabulation, taking into account the provision of
Regional Power.
 Produce a fault level calculation and stability study including the
effects of starting large motor drives and load shedding, to
confirm generator impedance and equipment selection
parameters. System stability analysis and voltage waveform
harmonic analysis should be considered.
 Prepare essential supplies requirements, (including load and
specification)
 Prepare a load shedding sequence and methodology.
DESIGN PHILOSOPHY Page 26
  Calculate and finalise dimensions of the electrical power system
and equipment to other disciplines and prepare layout of
switchroom and generator houses.
 Produce electrical protection system design.
 Produce lightning protection study.
 Identify cathodic protection requirements and determine most
appropriate system of protection. Document design and
acceptance procedure.
 Produce the distribution network design material take-offs.
Material take-offs shall be continuously kept up to date.
 Produce and maintain a comprehensive cable schedule and
register.
 Produce lighting design and layout and maintenance power
design.
 Prepare the electrical equipment schedule.
 Conduct a SAFOP Study (Electrical HAZOP), produce study
report and action register.
 Produce or update requisition packages for all electrical
equipment and materials and input to requisitions packages
having electrical content, including completion of data sheets,
schedules and drawings.
 Produce or update detail drawings including the following:
o Panel general arrangements.
o Cable transit details.
o Cable tray rack support details.
o Earthing details.
o Lighting, small power and associated control details.
o Cable trench section details.
o Lighting protection details.

 Size cable rack or trench to suit cable dimensions, segregation

and contingency requirements.
 Size cable transit frames to suit cable dimensions for groups of
cable entering buildings.
 Produce layout drawings showing the locations of all electrical
equipment and junction boxes (JB’s) etc. Drawings to include
cable rack layouts detailing dimensions and locations of all cable
rack.
 Produce and maintain the Hazardous Area Classification
drawings.
 Produce cable routing drawings detailing all electrical power and
control cables routing and identification up to “approved for
construction” status.

DESIGN PHILOSOPHY Page 27

  Produce earthing diagrams to cover the complete electrical
system and show earthing of the system neutral (with links
switchboard earth bars/switchboard steelwork.
 Produce AC distribution key diagram: the diagram shall indicate
the complete AC electrical system on the plant.
 Produce overall block cabling diagrams.
 Produce individual interconnection diagrams to show cabling
hook-up for particular systems and include cable numbers,
equipment number locations description, termination drawing
reference.
 Produce motor control schematics.
 Produce all termination diagrams.
 Provide wiring diagrams for all equipment.
 Produce material take-off based upon schedules, routing
diagrams and drawings.
 Prepare, issue and update philosophies/procedures for testing
the electrical systems.
 Review the isolation facilities provided for major equipment and
systems, and of the need for locking and interlocking with regard
to operational, maintenance and safety requirements.
 Log and manage electrical equipment certification.
7.6. Control and Instrumentation

7.6.1 The control and instrumentation scope for the design shall include but
not be limited to the following:

 Review and verification of conceptual study data, reports and

studies.
 Develop and finalise all aspects of instrumentation and control
design.
 Develop the requirements for maintenance and testing to
achieve the required Safety Integrity Level in accordance with
IEC 61508.
 Produce Instrument and Control design philosophy.
 Prepare all stand alone specifications and data sheets required
for the requisition and purchase of all instrument packages,
equipment and bulks.
 Prepare instrument index and database and update as data
becomes available to AFC status (Index shall include all
instruments, including package instruments).
 Prepare instrument data sheets. Continuously update those as
information becomes available.
 Produce calculations for the sizing of equipment, cabling and
tubing.
DESIGN PHILOSOPHY Page 28
  Manage and register key vendor calculations (e.g. control/relief
valve sizing, flow/restriction orifice sizing and thermowell
calculations).
 Prepare typical instrument mounting drawings for inclusion into
Packaged Equipment RFQ’s.
 Perform interface engineering with process control, safety shut
down and F&G system Vendors, including transfer to Vendors of
all required drawings and deliverables, including mechanical
package data (serial bit maps, etc).
 Prepare material take-offs based upon schedules, layouts,
routing diagrams and drawings, and include all cabling, tubing,
fittings, junction boxes, etc.
 Prepare graphic display backgrounds for process control, safety
shut down and F&G system Vendors.
 Prepare requisition packages for all instrumentation and process
control, safety shut down and F&G systems/equipment.
 Carry out technical review of bids and assist with bid
evaluations. Expedite Vendor drawings and resolve Vendor
queries.
 Develop and manage risk analysis sheets (area safe charts) by
fire area to detail fire and gas detection systems input and output
signals, indicating area classification, ventilation, combustible
hazards, passive fire protection and fire protection equipment in
each fire zone.
7.6.2 Prepare all necessary drawings to AFC status including:

 P&IDs (contribute to)

 Process Control narrative and diagrams
 Block Cable Diagram
 Instrument and Control Room Equipment layout drawings.
 Layout and location drawings showing instrument locations and
junction box locations
 Cable routing drawings
 Fire and gas detector locations.
 Motor Schematics tie-ins.
 Cause and Effect diagrams will be produced to include the PCS,
SS and F&G systems.
 Logic diagrams for Vendor Packages not covered by C & E
Diagram.
 Data highway communication Block Diagrams.
 Panel layouts.
 Process, Pneumatic, and Hydraulic hook-up drawings.
 Instrument loop and F&G loop diagrams.
DESIGN PHILOSOPHY Page 29
  Instrument installation details.
 Junction box termination diagrams.
 Junction box schedules.
 Vendor interface drawings.
 Cable schedules.
 Schedule of instrument equipment certification.
7.7. Telecommunications

7.7.1 The telecommunications scope for the design shall include but not be
limited to the following:

 Review and verification of conceptual study data, reports and

studies.
 Develop a telecommunications equipment list.
 Prepare telecommunications specifications and design for
enquiry equipment package.
 Carry out system design for all main systems.
 Prepare enquiry/purchase for all main systems.
 Prepare enquiry/purchase requisition.
 Review and incorporate Vendor data into the detail design.
 Prepare equipment block diagrams, layouts and installation
details.
 Prepare electrical hook-up and wiring diagrams.
 Prepare interfaces between the CPF, and the wells.
 Prepare material take-offs for cable and accessories.
 Participate in technical review of bids, expedite Vendor drawings
and resolve Vendor queries.
 Log and manage conformity of telecom equipment with
electrical, electronic and radiation emission standards.
7.8. Health, Safety and Environmental

7.8.1 The safety and loss control engineering work shall include, but not be
limited to, the following:

 Review and verification of conceptual study data, reports and

studies.
 Design of safety and fire protection systems in accordance with
the Operational Philosophies.
 Perform firewater hydraulic calculations on all fixed firewater
systems. Calculations to be produced and issued confirming
pumps and system capabilities based on hydraulic isometrics.
Firewater Report shall be produced including hydraulic

DESIGN PHILOSOPHY Page 30

 calculations and safe operation with regard to people and
equipment.
 Participate in safety reviews and audits.
 Participate in HAZOP studies, monitor HAZOP closeout and
prepare final HAZOP report in conjunction with the independent
HAZOP chairman.
 Manage the preparation of stand-alone specifications and data
sheets for the requisition and purchase of fire fighting and safety
equipment, including deluge valves, nozzles, monitors, hose
reels, hydrants, hose cabinets, foam skid, CO2 systems and
portable equipment.
 Manage and record the QRA associated with the Fire and Gas
hazards for the process plant.
 Specify the plant alarm standards, sounds, colours and area
sound level requirements.
 Identify incident communications requirements.
 Carry out technical review of bids and assist with bid evaluation.
 Prepare Process Safeguarding Flow Scheme and ESD valve
location review, including survivability analysis.
 Prepare Escape Route Plans and assembly area locations.
 Prepare incident response locations and requirements.
7.8.2 The Contractor shall prepare a Project Design Safety and
Environmental Plan as part of the overall Project HSE Plan to define
the scope of HSE work in the Engineering phase of the Project to
include:

 Maintenance of Project Safety Action Register.

 Preparation of Hazard Register and necessary Layout studies.
 Manual of Permitted Operations.
 Maintain the HAZOP dossier including register, HAZOP Review,
follow up and close out.
 Control of Substances Hazardous to Health in procured
equipment and materials.
 Security Design Manual.
 Simultaneous construction and operation safety requirements.
 HSE Engineering Technical Audits.
7.8.3 The Contractor shall carry out all Work in accordance with the HSE
Plan.

7.8.4 The Contractor shall collate all deliverables associated with HSE
engineering into an HSE Engineering Book.

7.9. Civil/Structural

DESIGN PHILOSOPHY Page 31

 7.9.1 The civil/structural design scope of work shall include the following:

 Review and verification of conceptual design data, reports and

reviews.
 Review and verification of soils conditions as per soils
investigation report.
 Review of Vendor data for loads, dimensions and holding down
details of equipment.
 Prepare detailed drawings for site preparation.
 Prepare detailed drawings for roads, fences and gates.
 Prepare detailed drawings for tank foundations and compounds.
 Prepare detailed designs and drawings for underground
services.
 Prepare detailed drawings for foundations and paving.
 Prepare detailed drawings for piperacks and pipe supports.
 Prepare structural detail drawings for buildings.
 Prepare detailed designs and drawings for all steelwork
structures (e.g. supports, platforms, canopies, staircases, floor
grating and plating, ladders, handrailing, crane rails, etc).
Structural steel designed and supplied by outside vendors will
not be duplicated.
 Prepare detailed designs and drawings for all equipment and
building foundations, roads, earthworks and all external works.
 Prepare final civil/structural material take-offs.
7.10. Architectural

7.10.1 The architectural design scope of work shall include:

 Development of building requirements for the facilities within the

fence.
 Review and verification of the conceptual design data.
 Prepare building specifications.
 Prepare architectural design drawings for all in-plant buildings.
 Prepare a MTO for plant buildings furnishings.
7.10.2 The Contractor shall design foundations and the required utilities
(water, electricity, drainage, HVAC, etc) for all the buildings.

DESIGN PHILOSOPHY Page 32

8. PROJECT ORGANISATION

8.1 A detailed project organisation chart shall be available from the start of
the design stage. The organogram should be added to, modified and
regular updates issued as the project progresses from Design to
Engineering, Procurement, Construction and Commissioning.

8.2 The organogram should show name, role and contact details (email,
telephone and fax number as a minimum).

8.3 The contractor is to produce a Project Procedures Manual and a

Project Execution Plan, which will be approved by SH

9. VENDOR SELECTION

9.1 All vendors will have to be on the Approved Vendor List supplied by
SH. Vendors not on this list will have to be approved by SH.

9.2 Vendor selection shall take into consideration, but not be limited to, the
following requirements:

 Selected vendors should have a comprehensive local support

network.
 Vendors should be able to send personnel to site as required by
SH for support.
 Vendors should have a proven track record in supplying similar
service or equipment in Algeria or other remote and harsh desert
areas.
 All equipment shall have been ‘tried and tested’ in a similar
environment.
10. TAGGING AND LABELLING

10.1 One standard tagging and labelling system shall be employed for the
whole facility. This should be consistently used and be logical for the
operation and maintenance personnel, and be included in the SH
system.

10.2 All equipment shall be individually tagged such that they are easily
identifiable in the field, and an aid to fault finding.

10.3 Pipelines and flowlines shall be colour coded and easily identifiable
from the air.

10.4 Large equipment such as vessels and tanks shall have clearly visible
tag numbers. All vessel name plates will be stamped with an Algerian
Government stamp after testing.

10.5 The format for ferruling of cabling and terminals should be agreed with
SH prior to commencement of detailed design. Ferruling shall be
consistent and standard across all the plant, including vendor
packages.

DESIGN PHILOSOPHY Page 33

11. DOCUMENTATION

11.1. General

11.1.1 All documentation shall be produced in French .

11.1.2 Documentation shall be produced and supplied in electronic format.

11.1.3 Documentation supplied on paper should either be converted to

electronic format or electronically scanned.

11.1.4 Document numbering shall follow a logical format and conform to the
project document numbering standard.

11.1.5 Document registers shall contain cross–references and shall list

items by:

 Tag number
 Purchase Order Number
 Supplier
 System

11.1.6 Document registers shall be searchable. Once a tagged item has

been located, it shall be possible to obtain references for the
following relevant documents:

 P&IDs
 Safeguarding Diagrams
 Cause and Effects
 Hazardous Area Classification
 Line List
 Data sheets (Design and Supplier)
 Supplier drawings
 Piping isometric and general arrangements
 Layouts
 Instrument layout and hook-up
 Cable numbers
 Alarm and Trip Schedule
 Safety Device Register
 Calculations
 HAZOP studies

11.1.7 Text shall be legible when documentation is reduced to A4 size.

11.1.8 The documentation system structure shall allow modifications,

additions and deletions resulting from post–design plant
modifications.

DESIGN PHILOSOPHY Page 34

 11.2. Process Flow Diagrams

11.2.1 These shall show the system in schematic form and cover any
modifications to the process design throughout field life.

11.2.2 A separate PFD for Test Separation shall be considered.

11.2.3 Heat and Material Balance tables shall be produced for each of the
system design cases.

11.2.4 Standard conditions shall be defined. It shall be clearly stated

whether volumetric flows are actual or standard, and whether they
are on a dry or wet basis.

11.2.5 Hydrate formation temperatures shall be stated.

11.2.6 Cross-references shall be made to relevant drawings, design reports

and calculations. The basis for the definition of pseudo-components
shall be stated or suitable references given.

11.3. P&IDs

11.3.1 These are controlled documents.

11.3.2 A Legend sheet shall be produced. This can include typical details
such as shutdown valve instrumentation and sampling skids.

11.3.3 Piping configuration shall reflect actual piping layout.

11.3.4 Demarcations between distinct areas of plant shall be shown.

11.3.5 All valves shall be identified with a unique tag number. If this leads
to over-crowding, then a separate drawing with irrelevant items
removed shall be produced.

11.3.6 Flow direction shall generally be from left to right. Main process
streams and vessel outlines shall have heavier line weights than
secondary/utility lines, and instrument signal lines should be lighter
again.

11.3.7 Continuation flags shall include the continuation drawing number and
appropriate description.

11.3.8 Piping specification breaks, tie-in points, and package interfaces

shall be clearly shown.

11.3.9 Drawings shall reflect ‘as-built’ and ‘as-commissioned’ status.

11.3.10 Elevations of major equipment items shall be shown.

11.3.11 Packaged items shown as a box shall contain reference(s) to

appropriate supplier drawings. Such drawings shall be included in
sets of drawings that are formally issued.

DESIGN PHILOSOPHY Page 35

 11.3.12 Non-standard piping items shall be assigned a unique Special Piping
item number.

11.3.13 P&IDs to be titled consistently throughout the plant. Pro forma title
block shall be agreed with SH prior to commencement of detailed
design.
11.4. Safety Device Register

11.4.1 This is a controlled document.

11.4.2 This is a register of system components that influence the safety of

the design. The purpose is that it will enable operations personnel to
assess if any proposed modifications could have a safety impact.
Typical examples are:

 Relief valves
 Trip settings
 Control valve trim sizes (for gas blowby relief cases)
 Fire proofing insulation
 Pump impeller size (may impact discharge pipe rating)

11.5. Safeguarding Diagrams

11.5.1 These are controlled documents.

11.5.2 These diagrams are based on the system PFD(s) and show the
location of safeguarding devices such as relief devices, blowdown
devices, shutdown valves.

11.6. Alarm and Trip Schedule

11.6.1 This is a controlled document that records these settings and

provides background information/references on the design thinking
behind the setting chosen.

11.7. Controller Tuning Parameters Register

11.7.1 This is a controlled document that records the tuning parameters for
plant controllers, including set points and controller actions, and
provides background information/references. It is envisaged that this
will be completed during plant commissioning. The register shall
include controller set points

11.8. Cause and Effect Charts

11.8.1 These are controlled documents.

11.8.2 These should be formatted such that any one input device and any
one output device only appears once.

11.8.3 They should be constructed in a logical manner on a system basis.

11.8.4 These should be able to be interrogated in both directions.

DESIGN PHILOSOPHY Page 36
 11.8.5 A Shutdown Logic Overview Diagram shall be produced that shows
the hierarchical structure of the shutdown system.

11.9. Vessel Level Co-ordination Diagrams

11.9.1 These are controlled documents.

11.9.2 These diagrams shall show the relationship between level instrument
ranges, level bridle lengths, vessel nozzles and actual vessel
elevations.

11.9.3 These shall be reviewed and approved by the designer’s Process,

Instrument, and Mechanical Departments.

11.9.4 Cross references to supporting documents such as vessel trim

drawings, data sheets, and vessel general arrangements shall be
included.

11.10. Hazardous Area Drawings

11.10.1 These are controlled documents.

11.10.2 These shall be based on plant layout drawings.

11.10.3 The designer’s Process Department shall produce a Hazardous Area

Datasheet to include equipment items as well as items such as
sample points, open vents, etc.

11.11. Instrument Layout Drawings

11.11.1 These are controlled documents.

11.12. Valve Registers

11.12.1 These are controlled documents.

11.12.2 These shall be produced on an equipment/system basis such that

they can be easily used in commissioning and start-up/operational
procedures.

11.12.3 Valves that have a special status (e.g. locked open) or form part of
an interlock system shall be clearly shown to have that function.

11.13. Data Sheets

11.13.1 These are controlled documents.

11.13.2 Design data sheets shall clearly state the design basis for the
presented data.

DESIGN PHILOSOPHY Page 37

 11.13.3 Supplier data sheets shall be legible and complete and make
reference to the design data sheet. Vendor data sheets shall be
supplied with the relevant calculations.

11.13.4 Supplier data sheets for process heat exchangers shall include
system volumes to assist blowdown calculations.

11.14. Special Piping Items Databook

11.14.1 This databook shall include a register of Special Piping items as well
as relevant design and supplier documentation.

11.14.2 The register shall cross-reference relevant P&IDs as well as piping

general arrangement and isometric drawings.

11.15. Vendor Documentation

11.15.1 Vendor documentation shall comply with project documentation

requirements.

11.15.2 Vendor documents shall be available for review prior to

commissioning.

11.15.3 The main contractor is to formally issue a complete and

comprehensive operating description. This shall include vendor, sub-
vendor and vendor skid operating details. This should not be a
compilation of photocopied vendor write-ups.

11.16. Fiscal Metering Dossier

11.16.1 Each fiscal metering system shall have a dossier. Each dossier shall
contain:

 A narrative description of the metering function, design

philosophy and operating procedures.

 P&ID’s of the process systems including the metering system.

 The design specification and manufacturers documentation for

the component parts of the system.

 The computer handbook showing the equations and routines

used.

 The detailed calculations of the metering system uncertainties.

 Inspection certificates.

 Calibration certificates.

 Witnessed results of system inspection and testing.

DESIGN PHILOSOPHY Page 38

  Details on calibration and verification methods, equipment used,
frequency of tests and results.

DESIGN PHILOSOPHY Page 39