Review of Regional SOPs

for
Engineering and Design
Series 200

New ASIA SOPs / GSOPs

ASIA-SOP-200

Engineering and Design

ASIA-SOP-201

Control of Engineering Software

ASIA-SOP-202

Checking, Approval and

Verification of Design

ASIA-SOP-203

Control of Design Change

ASIA-SOP-204

Technical Requisitions

ASIA-SOP-205

Design Reviews

Slide 2

New ASIA WIs

ASIA-WI-200-01

Equipment Numbering

ASIA-WI-201-01

Computer Aided Design

ASIA-WI-205-01

Hazard and Operability

ASIA-WI-205-02

Control of Hazard and

Operability

ASIA-WI-205-03

cGMP Review

ASIA-WI-205-04

Engineering for Construction and

Maintenance

Slide 3

Related ASIA-SOPs / GSOPs

ASIA-SOP-100

Project Management and Execution

ASIA-SOP-101

Control of Project Documentation

ASIA-SOP-110

Risk Identification and Management

ASIA-SOP-111

Opportunity Response

ASIA-SOP-130

Project Controls

ASIA-SOP-301

Project Quality Plans

ASIA-SOP-310

Client Surveys

ASIA-SOP-320

Quality Audits

GSOP-120

Multi-office Planning and Execution

Slide 4

Related Work Instructions

ASIA-WI-100-01

Project Co-ordination and

Reviews

ASIA-WI-100-02

Professional Services Coding

ASIA-WI-130-01

Planning and Scheduling

ASIA-WI-130-02

Estimating

ASIA-WI-130-03

Work Progress Measurement

ASIA-WI-130-04

Change Management

Slide 5

Major Difference
Changes to comply with GSOPs
More Precise
Responsibility and Action Oriented
Client Oriented
Emphases greater use of JVEPs
More user friendly format

Slide 6

Salient Features of ASIA-SOP-200 Engineering

and Design
Design steps in ASIA-SOP-200

Management and Coordination

Project Initiation and Planning

Design Verification Planning

Preparation of Engineering Deliverables

Design Verification and Interdiscipline Coordination

Design Validation

Design Changes

Construction Support, as required

Project close-out

Slide 7

Management and Co-ordination

Responsible : Engineering Manager

Defines interfaces between

engineering / design disciplines

Engineering / non-engineering groups

Ensures implementation of applicable QMS / project specific

documents

Appoints Design Safety Lead for the project

Maintains list of validated software

Establishes office standards, formats, technical information

requirements

Slide 8

Management and Co-ordination

Responsible : Discipline Managers
Establish CAD standards for all projects drawings
Ensure all softwares are verified and validated
Ensure trained staff
Establish / maintain / update Discipline Checklists

Slide 9

Management and Co-ordination

Responsible : Discipline Leads
Establish adequate coordination and communication

between Lead / Support Offices

Provide technically sound, safe and cost effective design
Ensure all design staff adequately trained in regional /

project specific procedures

Slide 10

Project Initiation and Planning

Responsible : Project Manager

Ensures all staff have a clear and accurate scope definition

Verifies PAR and adequacy of workhours against the scope

Agrees with discipline leads on project schedule milestones

Incorporates Design Basis in PP Manual and Risk Mitigation

Plan in PEP

Incorporates Design Change Control Procedures

Slide 11

Management and Co-ordination

Responsible : Project Engineer

Coordinates work of each discipline

Informs constantly LEs of all changes, project decisions,

new informations

Responsible : CAD / CAE Coordinator

Identifies client requirements for CAD / CAE and

electronic tools

Ensures consistent configuration of drawings to enable

transfers

Slide 12

Project Initiation and Planning

Responsible : Discipline Leads

Establish and implement a staffing plan that meets project budget,

schedule and quality

Prepare deliverables list against WBS coding with workhour allocation

Manage costs and provide accurate estimates to complete

Provide timely input for progress / productivity tracking / reporting

Conduct a review of basis of design / input documentation

Slide 13

Project Initiation and Planning

Responsible : Discipline Leads
Implement Design Basis in PP
Provide input to design safety and environmental plan
Implement design change control procedure
Establish discipline files

Slide 14

Project Initiation and Planning

Responsible : Construction Manager
Develops constructability objectives with input from project

team
Administers constructability process for the project (Ref

JVEP03 Constructability)
Documents all reviews, meetings and constructability cost

savings / avoidance

Slide 15

Project Initiation and Planning

Responsible : DPE
Conducts in depth first monthly review
Conducts subsequent monthly project reviews

Slide 16

Design Verification Planning

Responsible : Discipline Leads

Develop a Design Verification Plan

DVP to include design safety and constructability reviews

Plan / Schedule reviews alongwith Planning

Responsible : Engineering Manager / Discipline Manager

Identifies need for independent design review

Unproven design process

Unfamiliar technology / equipment

On conventional projects, choose deliverables which have a major

impact on delivery or that are complex
Slide 17

Design Verification Planning

Responsible : Project Manager
Ensures DVP aligns with project scope, size and

complexity
Issues DVP

Responsible : Engineering Manager and Discipline Manager

Review / approve DVP

Slide 18

Preparation of Engineering
Deliverables
Responsible : Design Leads

Prepare, review and deliver all required engineering

deliverables

Use established formats and approved cadding and 3Dprocedures

Ensure all engineering deliverables are checked and

approved

Prepare technical requisitions

Slide 19

Design Verification and

Interdiscipline Coordination
Responsible : Discipline Managers
Designate qualified checkers and reviewers must be

independent of documents originator

Responsible : Checkers
Check using checklists and DVP
Discuss comments with originator

Slide 20

Design Verification and

Interdiscipline Coordination
Responsible : Project Engineer

Ensures design review as per DVP are conducted

Ensures design reviews are documented and reported

Responsible : Project Manager

Ensures Interdiscipline reviews completed in time

Verifies design review actions as per DVP implemented

Slide 21

Design Verification and

Interdiscipline Coordination
Responsible : Discipline Leads

Ensure latest revision of documents / codes / procedures used

Resolve comment disagreements between checkers and originators

Initiate and control interdiscipline control activities

Establish 3D Model reviews, address the following :

Inter-discipline co-ordination

Client reviews

Construction review to address construction issues

Implement squad check reviews as per DVP

Slide 22

Design Verification and

Interdiscipline Coordination
Responsible : Engineering Manager / Discipline Manager
Verifies implementation of DVP and checking function

Slide 23

Design Validation
Responsible : Discipline Leads

Ensure resulting product capable of meeting requirements

of specified application
(If practicable, validation completed prior to delivery or
implementation of product)

Responsible : Discipline Managers

Ensure computer software is verified / validated as

required
Slide 24

Design Changes
Responsible : Discipline Leads
Highlight changes that impact cost, schedule and

workhours. Raise VN
Responsible : Project Manager
Expeditiously raise CN with client and resolve

Slide 25

Construction Support
Responsible : Construction Lead
Establishes procedures for documenting design activities

in support of construction activities including

RFI

Approval of design change

Updates to design drawings based on approved changes

Slide 26

Construction Support
Responsible : Project Manager
Incorporates procedures in PP Manual and Change

Management
Responsible : Discipline Leads
Prepare as-built or record drawings based on red line

drawings issued by construction site

Slide 27

Project Closeout
Responsible : Project Manager

Ensures

deliverables controlled, maintained and dispositioned

archived per project document control

Documents lesson learned on on-going

Responsible : Discipline Leads

Archive in accordance with retention requirements

Slide 28

Salient Features of ASIA-SOP-201

Control of Engineering Software

No major change from SOP-102

Software need not be revalidated every year (Ref. para 4.1)

Reverification necessary when current version

Is upgraded

Moved to a new operating platform

Moved to substantially new hardware platform

3-D electronic model to comply with

L WI 273 3D Modelling

L WI 275 3D Model Review

L WI 276 Clash checking

Slide 29

Salient Features of ASIA-SOP-202 Checking,

Approval and Verification of Design

Colour Coding changed (Ref. para 4.4, step 4.4.3)

Yellow Correct Content
Red Correction or addition required
Green Area to be deleted from deliverable
Blue Used to check-off corrections made and comments
Black Used for calculations, notes etc.

DVP modified. Engineering Manager shall also approve DVP (refer S202f1)

Discipline Manger reviews a percentage / minimum list of deliverables in each

project

Discipline Checking and Approval Matrix modified (refer S202f2)

Slide 30

Salient Features of ASIA-SOP-203 Control of

Design Change
No major change

Slide 31

Salient Features of ASIA-SOP-204 Technical

Requisitions
No major change
Coding Index for piping marginally modified. (refer

S204f4)
Eventually, need to comply with ASIA-SOP-402 Inquiry

Requisitions and Inquiry Documents (under process)

Slide 32

Salient Features of ASIA-SOP-205 Design

Reviews

Plan design reviews based on project scope, application and criticality

Design reviews broadly are :

Independent Design Review (IDR)

Interdiscipline Squad checking

Interdiscipline Model Review

Design Safety Review

Hazop Review

CHAZOP Review

cGMP Review

Constructability and Risk Assessment Reviews

Slide 33

Design Review Implementation

Responsible : Discipline Lead

Generates Design Verification Plan

Organises review

Responsible : Discipline Manager

Reviews Design Verification Plan

Ensures verification checks completed

Engineering Manager

Reviews / approves Design Verification Plan

Slide 34

Independent Design Review

Responsible : Lead Engineer and Project Manager

Agree for IDR with Discipline Manager / Engineering Manager

Responsible : Discipline Manager

Nominates qualified Design Reviewer

Responsible : Design Reviewer

Establishes that Design processes used

provide technical integrity

meets contractual requirements

Generates Review Report (refer S205f1)

Discusses findings with Design Lead

Slide 35

Independent Design Review

Responsible : Project Manager
Ensures findings are implemented in a timely manner

Slide 36

Interdiscipline Squad Checking

Responsible : Originating Discipline Lead

Ensures DVP incorporates squad checking

Initiates and controls individual squad checking activities (refer

S205f2)

Establishes method of review viz sequential, parallel or review in a

meeting.

Squad check comments

Reviewed / compilation

Reviews with PM re : implication

Incorporates comments into deliverables

Slide 37

Interdiscipline Model Review

Phase 1, 2, 3 reviews (ref. L WI 275 PDS-3D Model Review)

Phase 1- 30% progress Space Allocation Review

Phase 2 60% progress Preliminary Piping Routing

Phase 3 90% progress Detailed Allocation Review

(Final Design)

Joint discipline reviews at regular intervals to check for safety,

operation, maintenance

Discipline Leads to review modelling on a day-to-day basis using

Smart Plant Reviewer
Slide 38

Design Safety Review

Responsible : Project Manager

Owns overall responsibility for safety

Responsible : Design Safety Lead

Establishes with Discipline Leads design safety activities

necessary

Ensures same identified in respective DVP

Establishes Design Safety Register (refer S205f7).

Ensures all concerns are adequately actioned
Slide 39

Design Safety Review

Responsible : Discipline Leads / Task force members
Raise, record and resolve all design safety concerns (refer

S205f8)

Slide 40

Design Safety and Environmental Plan

Responsible : Design Safety Lead and Project Manager
Agree for and prepare Design, Safety and Environmental

Plan (refer S205f5)

Slide 41

Design Safety and Environmental Reviews

Responsible : Design Safety Lead and Project Manager

Identify and agree with client the review activities required.

Phase 1 Design Safety Specifications
Phase 2 Design Safety Review
Phase 3 Hazop
Phase 4 Post Hazop Review
Phase 5 Pre-commissioning Safety Review
Phase 6 Hazops arising from construction activities

Responsible : Project Team

Conduct reviews
Slide 42

cGMP Review
Undertaken to ensure that a design and / or facility

conforms to cGMP requirements (Ref. ASIA-WI-205-03

cGMP review)
No. of cGMP Checksheets increased from 11 nos. to 23

nos.

Slide 43

Constructability Review
Refer ASIA-WI-200-04 Engineering for Construction and
Maintenance (no major change)
Objective
Construction risks are identified
Identified risks are minimised (from an engineering and

design perspective)

Slide 44

Constructability Review
Refer ASIA-SOP-501 Constructability Review (generally simplified)
Objective

Brings construction input into design engineering effort

Constructability process embraces five fundamentals :

Bring constructability into the project team as a participating

discipline early

Create and form a start-up driven engineering schedule

Use construction specialists as a critical resource during all

phases of the engineering process

Slide 45

Constructability Review

Capture and disseminate past lessons-learned and

standard practices

Slide 46

New Forms

S202f1

Design Verification Plan

S202f2

Discipline Checking and Approval Matrix

S204f4

Coding Index (A few Piping Prime Codes added)

WI200-01f1

Equipment Numbering

WI205-03f1

cGMP Review Meeting Compliance Matrix

WI205-03f2 to

cGMP Checklist (various) 20 nos.

WI205-03f13

WI205-03f14

Typical Agenda for cGMP Meeting

WI205-03f15

Typical Table of Contents for cGMP for a cGMP

Compliance Package

Slide 47