Front End Loading (FEL) and Process Engineering Workflow

Abstract

Project development for the oil refining industry is typically performed through a process called Front End Loading (FEL). In recent years, the Process and Industrial Division of Burns and McDonnell has performed several FEL efforts for various refining industry clients. A review of past FEL efforts indicates significant variation in the FEL deliverables provided, the content of these deliverables, and the overall quality. The primary objective of this field project report was to perform a review of past projects, and develop a comprehensive list of "standard" FEL deliverables. Once these deliverables were defined, a review of engineering workflow activities for each stage of the FEL process was performed. The list of deliverables and the engineering workflow activities provide a solid basis for the planning and execution of future FEL efforts.

As a byproduct to this report, a standard FEL sample report was also developed. This sample report is intended to benefit the division in three areas; 1) as a training tool for the introduction of FEL to new employees, 2) as a template or guide for future FEL efforts, and 3) as a sales tool for the demonstration of an FEL document to potential clients.

Finally, several recommendations were made regarding the management of an FEL, effort, execution of FEL engineering, and the transition of FEL to detailed design. For management of FEL, four key recommendations have been identified: • Use of a 3-Phase FEL approach. • Managing and maintaining consistent client “buy-in” throughout the FEL process. • Utilizing early involvement of individual design disciplines and construction. • Conducting PDRI reviews following each stage of FEL to measure progress. • Use independent FEL benchmarking for larger or more complex projects.

For execution of FEL engineering, four key recommendations were identified: • Emphasis on the development of a written Process Design Basis in early FEL. • Focus on thorough documentation of design assumptions by individual engineering disciplines. • Obtain operations input from the client in early FEL. • Improve quality review procedures specifically for FEL projects.

Finally, five recommendations were made for transition of FEL to detailed design. • Maintain strong continuity of project team, specifically with lead engineers and piping designers. • Improve format standards for FEL data to streamline communication of data in detail design. • Maintain adherence to FEL design assumptions were at all possible to minimize scope creep. • Limit unresolved issues from FEL by conducting a final open items review to track all uncertain or outstanding issues prior to start of detailed design. • Implement management of change process in FEL to ease transition to detail design.