Section 2 — Documentation Requirements
Plant Manuals
IPE Engineering Practice IPE-EP-2-4-1
Document number: IPE-EP-2-4-1 · Section: 2 — Documentation Requirements
SCOPE
- This Practice covers the requirements for developing the layout, format and organization of Plant Manuals. In general, Plant Manuals shall be developed for projects with capital costs exceeding $5 million.
- Any deviation to this Practice must be approved by the procedure described in EP 1–1–3.
- An asterisk (*) indicates that a decision or approval by the Owner or the Owner’s Engineer is required, or that additional information is furnished by the Purchaser.
2.0 REFERENCES
The latest edition of the following standards and publications are referred to herein.
STANDARDS AND PUBLICATIONS
DEFINITIONS
- Contractor - Company or business that agrees to furnish materials or perform specified services at a specified price and/or rate to the Owner.
- Owner - Inflection Point Engineering, LLC.
- Owner’s Engineer - A Inflection Point Engineering, LLC. appointed engineer.
- Plant Manual - “As Built” Specification Book or Job’s Specification Book containing conformed data sheets, project specifications, Project drawings, equipment drawings, equipment lists, drawing lists, material balance sheets, etc.
GENERAL
- Plant manuals shall be completed as part of the project close out procedures.
- Plant manuals shall be developed to supply the plant with all pertinent design and maintenance information.
- (*)The manuals shall include the items shown in Table 1, unless otherwise specified by the Owner’s Engineer.
- (*)Separate Plant Manuals shall be developed for individual plant units or areas in which major operating facilities are revamped or constructed, unless otherwise specified by the Owner’s Engineer.
- Drawing size to be a maximum of 11 X 17 inches.
FORMAT
- The Plant Manuals shall be organized by section number corresponding to EP 1–0–1.
- All project information including Project Specifications, data sheets, equipment design and vendor drawings shall be organized with tabs identified by the EP index section number as shown in Table 1.
BOOK DESIGN
- As a minimum, the book covers shall be designed as shown in Figure 1 and Figure 2.
- (*)Bindings shall be post design with a minimum of four posts.
- Binders shall nave 3 inch capacity for 8–1/2 x 11 inch sheets.
- (*)Binder Cover material shall be binder board covered with buckram cloth or other covering material as specified by the Owner’s Engineer.
- Each binder shall have tabs corresponding to the standard format described in section 5.0 of this Practice.
- (*)Additional tabs may be included as per Owner’s Engineer.
- Tabs shall be 2–1/2 with 1/2 inch extension.
- (*)Tab font shall be arial and point size as specified by the Owner’s Engineer.
- (*)Tabs extensions and hole strips shall be laminated on front and back.
- Manual cover and tab colors shall be designated by the Owner’s Engineer.
7.0 TABLES
TABLE 1
PLANT MANUAL DOCUMENTATION
| SECTION | ITEM | SUPPLIED INFORMATION |
|---|---|---|
| 1 | General | -General Description of Plant Operation -General Unit Descriptions --Deviations to IPE Engineering Practices |
| 2 | Design Requirements | -Design basis, process description -Basic Engineering Design Criteria -Feed Properties and product specification -Plant heat, mass, and utility balances -Piping & instrument diagrams -Process flow diagrams -Utility flow diagrams -Drawing index -Site meteorological data -List of specifications used |
| 3.1 | Plant Layout | -Plot plans -Equipment list -CADD drawing cross reference -Applicable elevation drawings -Site survey, soils, and geotechnical reports |
| 3.2 | Safety Systems | -Safety/Loss prevention design philosophy -Area classification drawings including lists of sources of hazard -Fire prevention systems -Safety/Pressure relief valve list/Data Sheets -Pressure relief design philosophy and calculations -Safety Equipment and Plot Plan |
| 3.3 | Environmental | -List of effluents and emissions, calculated emissions, and effluents and methods of disposal –Air Permits, Building Permits -Hazardous substances lists as appropriate |
| 4 | Structures and Foundations | -Foundation calculations -Piling calculations -Structural calculations |
| 5 | Piping | -Line lists -Tie-in List |
TABLE 1
PLANT MANUAL DOCUMENTATION (cont.)
| SECTION | ITEM | SUPPLIED INFORMATION |
|---|---|---|
| 6 through 9 | Rotating Equipment, Pressure Vessels, Heat Exchangers, Fired Heaters and Boilers, Cooling Towers and Tankage (by equipment type) |
-Purchase Orders -Data sheets -Calculations(2) -Manufacturer’s reports(2) -Fabrication drawings(2) -Equipment design drawings(2) -Nameplate Rubbing(2) -Vendor Bill of Materials(2) -Operating instructions(2) -Maintenance Instructions -Spare parts list(2) -Hydrotest, pressure and performance test reports(2) |
| 10 | Material Requirements | Material Selection Diagram |
| 11 | Refractory, Insulation and Fireproofing | -Insulation calculations -Insulation schedules -Fireprooofing schedule |
| 12 | Instruments and Controls | -Data Sheets -Loop diagrams -Electrical and instrumentation -Interconnection diagram -Instrument list, Index -Instrument cable schedule and junction box -Distributed control system drawings -Logic diagrams |
| 13 | Electrical | -Electrical circuit diagram (single line diagrams) -Underground services drawing -Cable schedule -Electrical Area Classification Drawings -Data sheets and calculation for switchgear -Motor list (data sheets are included with corresponding machinery as appropriate) |
| 14.0 | Equipment Protection | -List of equipment with special winterization requirements |
| 15 | Inspection | -Field PMI test records -Cross reference of all testing and NDE records for piping |
TABLE 1
PLANT MANUAL DOCUMENTATION (cont.)
| SECTION | ITEM | SUPPLIED INFORMATION |
|---|---|---|
| 16 | Process Safety Management | -PSR reports -HAZOP reports -MSDS sheets |
| 17 | Project Quality Assurance | -All design changes issued for the project together with the Control Log. These changes shall be filed in numerical order. Supporting documentation shall also be included. |
NOTES:
- A cross–reference index to the drawings may be appropriate.
- All information is typically supplied as Vendor information. The manuals as supplied by Vendors shall be retained complete in their original binders and shall be assigned an appropriate reference number by the Owner’s Engineer.
8.0 FIGURES
FIGURE 1 PLANT MANUAL COVER
FIGURE 2 PLANT MANUAL SPINE
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