DOCUMENTATION REQUIRED OVER PROJECT LIFE CYCLE

GUIDELINES FOR APPLYING DELIVERABLE STATISTICS TO THE PROVISION OF OUTSOURCED ENGINEERING DESIGN AND PROJECT MANAGEMENT DOCUMENTATION

Pro rata Design Costs Engineering design costs as a percentage of the total project installed cost (TIC) vary from project to project as they are dependent on, amongst other things, the type of plant and the size of the plant, the complexity of the design and the level of detail provided to the design office. Typically design costs as a % of the TIC fall into the following ranges. Design Element Feasibility Design Front End Design Detail Design CDM and Risk Management (CDM Project HS File & Plan) Planning Supervisor Construction management (CDM Notifiable site) including Principal Contractor Types of Engineering Documents (Deliverables) The types of deliverables normally produced on a typical multidisciplined capital project in the Chemical/Fine Chemical industry include :Type of Engineering documents (Drawings on ACAD R14 or LT) Layouts and Plot plans Piping and General Arrangements Process Flow diagrams Process P&IDs Process Hook ups - Break ins Piping Isometrics As builts Engineering Manhours per drawing 40 60 20 30 4 2 1 Draughting Manhours per drawing 50 80 12 25 2.5 6 6 Checking Manhours per drawing 25 30 8 15 1 3 2 Percentage 1-2 5-10 15-25 12-20 5-10

Other Engineering Documentation (Deliverables) Type of Document (Electronically generated) Technical Specifications Hazard and operability studies CDM Health & Safety File (Phase 1) CDM Health & Safety Plan (Pre Tender) Planning and scheduling Gantt Charts Non Technical Documentation Type of Document Placement of Purchase orders (Simple) Placement of orders (Complex) Clerical Manhours/order 2.5 30 Engineering Manhours per document 30 40 40 30 20 Checking Manhours per document 5 10 4 8 4

DOCUMENTATION REQUIRED OVER PROJECT LIFE CYCLE

Quantity of documentation The amount of documentation produced on a typical project has become quite considerable and should not be underestimated. The 1994 CDM regulations place a legally binding responsibility on the part of the Client to ensure that the designers, planning supervisors and principal contractors are all competent. Notifiable projects require a considerable amount of supporting documentation in order to satisfy the HSE. Failing to ensure that the designer, planning supervisor and principal contractors are appointed, and competence are two offences that can be committed under section 33 of the 1974 Health & Safety at Work Act. Failing to ensure that the Health & Safety File and Health & Safety Plan are prepared and available for inspection are also offences that can be committed by the Client.

Project Value No of drawings No of purchase orders Vendor documents CDM Risk assessments Change and Variation orders

Phase Design Award Design Construction Construction

$ 2M 200 50 700 30 10

$ 10M 750 200 2500 50 20

$ 30M 2000 350 6000 300 50

$ 80 M 7000 650 14000 6000 120

The data provided above is purely indicative and should be used as a rough guide only. A MORE COMPREHENSIVE LIST OF THE DOCUMENTATION THAT IS TYPICALLY FOUND ON MULTIDISCIPLINARY CDM NOTIFIABLE CAPITAL PROJECT IS LISTED SEPARATELY.

DOCUMENTATION REQUIRED OVER PROJECT LIFE CYCLE PHASE 1 FEASIBILITY DESIGN CDM competences & key appointments Project Description & Design Spec. Equipment Schedule Process Calculations Process flow diagrams Process description Control philosophy Preliminary project schedule (Gantt) Hazops 1 & 2 IPCC Implications (EA) Statutory notices (EA) Order of magnitude estimate +- 30% Audit 1 Pre Sanction PHASE 2 FRONT END DESIGN PHASE 3 DETAIL DESIGN PHASE 4 CONSTRUCTION

CDM Pre tender File Equipment data sheets Safety & Environmental Audit (Process) Environmental impact study Fire Protection study Piping and Instrument diagram User requirement specification Instrument data sheet Electrical load list Electrical area classification Site survey and Plot plan General arrangement drawings Geotechnical data Control Philosophy CDM HSE plan Civil specification Civil and building drawings Structural drawings Detailed project cost estimate +- 20% Audit 2 60% Project Audit

DOCUMENTATION REQUIRED OVER PROJECT LIFE CYCLE PHASE 1 FEASIBILITY DESIGN PHASE 2 FRONT END DESIGN PHASE 3 DETAIL DESIGN Method statements for construction RC & Bar bending schedule Construction Risk assessments Design calculations Electrical specifications Pipework GAs Pipework Isometrics Fire protection drawings Insulation specification and schedule Material schedules Electrical single line diagrams Electrical schematics Electrical layouts Electrical schedules Instrument schedules Instrumentation/control user requirement Instrumentation specifications Loop sheets and diagrams Process hook up diagrams Material take offs Enquiry documents Technical requisitions Purchase orders Cost status reports Construction programmes Hazop 4 O&M manuals Commissioning manuals PHASE 4 CONSTRUCTION

Activity Day diary sheets Health and Safety Plan Construction risk assessments Method statements Variation and Change orders Completion handover documents As builts Audit 3 Construction Completion