Security Level 2

G R-T E G
1-1000-004
ISSUED AUG.16,’11

ENGINEERING GUIDE FOR PROCESS PLANT

DESIGN GENERAL

GUIDELINE FOR ENGINEERING INSTRUCTION TO

CONSTRUCTION

Unless stamped “CONTROLLED”, any hard copy from TEC-STANDARD database is handled as “Non-controlled”.
Users should confirm any time that the copy is the latest version.

L TOYO ENGINEERING CORPORATION

TOKYO JAPAN

GR-TEG1-1000-004h.doc
 Security Level 2

TOKYO L JAPAN
ENGINEERING GUIDE FOR PROCESS PLANT G R-T E G
TOYO ENGINEERING CORP. DESIGN GENERAL 1-1000-004
GUIDELINE FOR ENGINEERING INSTRUCTION
TO CONSTRUCTION
ISSUED AUG.16,’11 PAGE 1 OF 2

CONTENTS

1. GENERAL 2

1.1 Objectives 2
1.2 Scope 2
1.3 Application Notes 2
1.4 References 2

2. GUIDELINE 2

2.1 List of Engineering Instruction to Construction 2

2.2 Cover Sheet 2

Appendix (1) List of Engineering Instruction to Construction (P.1/3-3/3)

Appendix (2) Sample of cover sheet (P.1/1)

History (P.1/1)

GR-TEG1-1000-004.doc
 Security Level 2

TOKYO L JAPAN
ENGINEERING GUIDE FOR PROCESS PLANT G R-T E G
TOYO ENGINEERING CORP. DESIGN GENERAL 1-1000-004
GUIDELINE FOR ENGINEERING INSTRUCTION
TO CONSTRUCTION
ISSUED AUG.16,’11 PAGE 2 OF 2

1. GENERAL

1.1 Objectives

This guide defines the process of issuing Engineering Instructions, including content and timing, from each
engineering disciplines to construction division.
There exists established procedures to issue deliverables such as P&ID, Data Sheets, and drawings. However, no
procedures are available to issue Engineering Instruction to Construction. As a result, sometime such
instructions are prepared based on each assign engineer's understanding and issued by Letter Management
System (LMS).
This guide aims to eliminate such non-uniformity of each assign engineer's manner, and to provide them a
satandardized procedure to issue applicable Engineering Instruction to Construction in timely manner.

1.2 Scope

This guide is applied for all EPC projects in principle, except for cases where construction is out of scope.
For any project's specific deviation/exception to this guide, it is necessary to be approved by General Manager of
each engineering division.

1.3 Application Notes

This guide is limited to the internal use in Toyo between engineering disciplines and construction division. Third
party such as client, subcontractors and JV/Consortium Partners is not supposed to be included.
Even though for internal use, the instructions shall be written as considering the quality of expression in
instructions shall be described as a third party's understand level. For specific project requirement, handling and
distribution of instructions to a third party shall be determined and approved by construction division.
In addition, this guide shall be customized to suit specific project's contract requirements.

1.4 References

Following Toyo-Japan's standards are used as reference in this guide. Each Global Toyo company shall refer
comparable local standards and guides.

TMS0-101 : DESIGN CONTROL [C.Q.P]

TMS1-10002 : WORK EXECUTION PROCEDURE FOR ENGINEERING DESIGN
TMS1-10003 : COMMON AUTHORIZATION STANDARD FOR ENGINEERING DESIGN
TMS1-10401 : CONTROL OF DOCUMENT & DATA FOR ENGINEERING DESIGN
GM-TEG1-6220-203-1: DOCUMENT CONTROL PROCEDURE

2. GUIDELINE

2.1 List of Engineering Instruction to Construction

Instruction items, timing of issue and issue forms of Engineering Instruction to Construction are specified in
Appendix(1).

2.2 Cover Sheet

Engineering Instruction to Construction shall be issued with cover sheet. Sample of cover sheet is attached in
Appendix(2).

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GR-TEG1-1000-004
Appendix(1)-1/3
Appendix(1) List of Engineering Instruction to Construction
Before AFC After AFC
Pre-
Disciplines Instruction Items Timing of Issue Pre AFP AFD AFC comm Issue Form Remarks
Process The scope of chemical cleaning After issuance of AFC ●
Engineering Instruction
P&ID (Marked-up P&ID)
The scope of built it clean Before construction of Engineering Instruction
●
piping (Marked-up P&ID)
System boundary& schedule for M/C After issuance of AFP ●
Engineering Instruction
P&ID (Marked-up P&ID)
Arrangement of temporary facilities Before implementation Engineering Instruction
for pre-commi./commissioning of pre-commi./ ● ●

activity commissioning activity

Preservation procedure for Prior to intermission of Project procedure
suspension of project construction ●

The scope of water prohibited piping Before issuance of AFP ●

Engineering Instruction
against pressure test P&ID (Marked-up P&ID)
Flushing concept including scope of After issuance of AFC Engineering Instruction
permanent and temporary facility P&ID ●

which will be utilized

Arrangement of temporary valve and Before implementation Engineering Instruction
piping for pre-commi./commissioning of pre-commi./ ● ●
activity commissioning activity

Facilities Construction BQ for planning After receiving vendor Engineering Instruction

Engineering quotation, or earlier
●
Division stage by In-house
estimation
Vendor erection manual and other Vendor document check ID check or Vendor
key documents for handling and document distribution
erection at site such as GA with ●
weight, shipping sketch, erection
spare parts list, site preservation
procedure, etc.
List of key documents for Preliminary: After 1st Engineering Instruction
construction such as package issue of the key (Summary Table)
equipment plot plan, GA with weight, documents,
● ●
shipping sketch, erection spare parts Final: Equipment FOB
list, site preservation procedure,
Vendor document list, etc.
Scope of accessories and construction Preliminary: After 1st Engineering Instruction
material, and their supply condition issue of the key (Summary Table)
documents, ● ●

Final: Equipment FOB

- Anchor bolts/nuts and template ￬ ● ● ￬

- Liner plates, jack bolt, etc. for ￬ ￬
● ●
leveling of equipment
- sliding plate for horizontal ￬
● ●
￬
equipment
- Initial filling of lubricant, ￬ ￬
● ●
Flushing oil
- Lifting beam, wire, & shackle ￬ ● ● ￬
- Instrument/Electrical components ￬ ￬ (with sketch)
● ●
and their wiring/tubing
- lighting ￬ ● ● ￬
- Motor RCU ￬ ● ● ￬
- cable tray ￬ ● ● ￬
- Pre-fabricated pipe spools and ￬ ￬
pipe in commercial length for ● ●
interconnecting piping

- Welding rods for field welding ￬ ● ● ￬

- Insulation, steam trace ￬ ● ● ￬
- Touch-up paint ￬ ● ● ￬
- Construction spare parts ￬ ● ● ￬
Special notes for construction Preliminary: After 1st Engineering Instruction
such as PWHT by process reason, issue of the key (List)
bolting by documents, ● ●

torque wrench or bolt tensioner, Final: Equipment FOB

special preservation if required, etc.
Communication channel with Vendor Equipment FOB ●
Engineering Instruction
(List)
Requirement of Vendor supervisor For schedule and Engineering Instruction
●
manning
Equipment Supply split between Equipment Prior to start of Engineering Instruction
components supplied by different construction work. ●

fabricators.
Supply split between Equipment and Prior to start of Engineering Instruction
the following: construction work.
- Mechanical Erection
- Piping Work
- Electrical Work ●

- Instrument Work
- Civil Work
- Insulation Work
- Painting Work
Critical specifications required to Prior to start of ●
Engineering Instruction
achieve performance construction work.
General construction requirement for Prior to start of Engineering Instruction
●
safety and quality construction work.
Feedback from TOYO construction Prior to start of ●
Engineering Instruction
for similar plant. construction work.
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Appendix(1)-2/3
Appendix(1) List of Engineering Instruction to Construction
Before AFC After AFC
Pre-
Disciplines Instruction Items Timing of Issue Pre AFP AFD AFC comm Issue Form Remarks
Equipment Requirement by Licensor, Prior to start of Engineering Instruction
(cont.) Requirement of inspection and record construction work. ●

prior to commissioning
Elec. Drawing list and formats of At KOM with Engineering Instruction
drawings, requisition list, delivery subcontractor (Before
schedule, pre-commissioning construction
requirements, progress control key commencement at ●

B/Q, as-built information latest)

requirements
Any specific requirements (e.g. Before applicable Engineering Instruction
change of types of materials, special construction ●

details not covered in Typical, etc.) commencement

Control & Change items* on delivered control Before commencement Engineering Instruction
Instrumentati system equipment, field of final site inspection
on instrumentation devices and and test
Engineering associated materials (*Change items ●

Division of which change (replacement,

modification, etc.) will be carried out
at site after delivery).
Punch items* at Factory Acceptance After completion of Engineering Instruction
Test (FAT) of control systems control systems’ FAT
(*Punch Items of which close out will ●

be carried over to site).

Civil and Category-1 ; Instruction about construction sequence of structures.
Architectural （Special consideration from view point of structural design and installation of other facilities. ）
Engineering Timing of concrete slab casting for Time of relevant AFC Engineering Instruction
Division electrical panel supporting floor in drawing issuance ●

substation.
Equipment support structure and Time of relevant AFC Engineering Instruction
equipment installation. (specially for drawing issuance ●

complicated large scale structure)

Pipe rack and pipe installation. Time of relevant AFC Engineering Instruction
●
drawing issuance
Required construction sequence by Time of relevant AFC Engineering Instruction
structural design. drawing issuance ●

Project specific item and others, if Time of relevant AFC Engineering Instruction
any. drawing issuance or
one(1) month before ●

relevant construction
starting
Category-2 ; Instruction about construction tolerance/accuracy.
(Special consideration from view point of applicable code, process scheme and structural design.)
Road location, road width and road Time of relevant AFC Engineering Instruction
●
head clearance drawing issuance
Wall thickness and Internal Time of relevant AFC Engineering Instruction
●
dimension of pit/dike/spill wall/etc. drawing issuance
Elevation of top of beam for RC pipe Time of relevant AFC Engineering Instruction
●
rack drawing issuance
Location of equipment Time of relevant AFC Engineering Instruction
foundation/structure where large size drawing issuance ●

piping tightly connects to equipment.

Project specific item and others, if Time of relevant AFC Engineering Instruction
any. drawing issuance or
one(1) month before ●
relevant construction
starting
Category-3 ; Special notice about method(control) of construction
Bench mark(s) of surveying One(1) month before Engineering Instruction
Civil construction ●

starting
Subsoil for foundations One(1) month before Engineering Instruction
(incl. piling foundation) Civil construction ●

starting
Piling One(1) month before Engineering Instruction
Civil construction ●

starting
Heavy welding on insert plate one(1) month before Engineering Instruction
(control of welding heat input) relevant construction ●
starting
Project specific item and others, if Time of relevant AFC Engineering Instruction
any. drawing issuance or
one(1) month before ●

relevant construction
starting
HSE Engineering Instruction for Fire Within one month after Engineering Instruction
Engineering Protection System Summary submission of AFC ●

P&ID
Engineering Instruction for Filed Within one month after Engineering Instruction
Fire Fighting Equipment Installation submission of AFC fire
●
fighting equipment
layout
Engineering Instruction for Building Within one month after Engineering Instruction
Fire Fighting System Installation submission of AFC ●
P&ID

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Appendix(1) List of Engineering Instruction to Construction
Disciplines Instruction Items
Piping Category-1 ; Piping Field Instruction to be issued to Construction Group
Vendor's Deviations in Pipe Wall
Thickness
Vendor's Deviations in Delivered Pipe After purchase order
Length
Piping Material Substitution Plan
Scope of Supply for Bolts/Nuts at
Special Tie-in Applications
Scope of Supply / Work for Cathodic
Protection System
Category-2 ; Piping Field Instruction to be issued after confirmation with Construction Group
BOM Node Structure in Material
Management System (SP-Mat)
BOM to be controlled in Material
Management System (SP-Mat)
Data Sheet for Special Bolts/Nuts
Scope of Supply for Pipe Support
Materials
Construction Document for Special
Piping System (such as GRP, lining
piping etc.)
Construction Document for Duct /
Chute System (Urea/Granulation
Unit)
Post Weld Heat Treatment of Cr-Mo
Steel
GR-TEG1-1000-004a1.xls
Timing of Issue Pre
After purchase order
After issuance of piping
isometric drawings.
After purchase order
After purchase order
When the project starts
●
When the project starts
●
After purchase order
Minutes of meeting
● In addition, engineering shall clarify the delivery
After purchase order
(before the contract
with construction sub-
con)
After purchase order
(before the contract
with construction sub-
con)
After purchase order
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Appendix(1)-3/3
Before AFC After AFC
Pre-
AFP AFD AFC comm Issue Form Remarks
Engineering Instruction Inform the vendor's deviations in the pipe wall
thickness for material control in the material
management system (SP-Mat in Toyo's standard).
If any deviations in the pipe wall thickness,
● ● ●
discrepancies between the actual item and the
ident code information would be observed in the
warehouse, that will confuse the material control
at site.
Engineering Instruction Inform the deviations in the delivered pipe length
for BQ calculation and weld mapping by
● ● ● construction.
(Note; Toyo's standard requirements in the
delivered length is specified in the requisitions.)
Engineering Instruction Inform the plans of the higher-grade material
substitutions for the lower-grade applications of
● piping materials, that was intended when deciding
order quantities for purchasing.
Engineering Instruction Provide the information about the scope of supply
for bolts / nuts at the special tie-in applications
such as PSV inlet, tapped holes on the special
● valves and special equipment nozzles. For these
applications, it is difficult to identify the scope of
supply by referring only piping isometric
drawings.
Engineering Instruction (As necessary;)
Provide the information about the scope of supply
● / work by the cathodic protection vendor, in order
to decide the scope of work and supply by the
construction contractor.
Engineering Instruction Confirm and decide the appropriate BOM node
structure between construction and engineering in
order to suit to the project organization and the
warehousing system at site.
Engineering Instruction Confirm and decide the bulk item NOT controlled
by ident level (i.e. controlled by lot level), such as
pipe support structural steel and spool piping
systems etc.
Engineering Instruction Provide data sheet for piping special bolts / nuts to
supplement the "description" in the BM sheet,
since it is difficult to identify the detailed
information of these bolts / nuts by referring only
the description in the BM sheet, such as length
● and applicable location etc..
(Note; For special bolt "SBS" based on piping
MTO, UNIT of special bolt will be specified as
"set" due to MMS system limitation.
Instead, the numbers of required pieces will be
included into material description. )
Engineering Instruction Confirm and decide the scope of supply for the
support materials, i.e. construction sub-contractor
or Toyo's engineering.
condition of the pipe support materials, such as
clamp shoe, or U-band support etc.
Engineering Instruction (As necessary;)
Provide the instruction about the contents of
construction document, and the scope of material
●
supply and work by vendor, since the scope of
supply and work are sometimes split into several
parties (i.e. several vendors and Toyo).
Engineering Instruction (As necessary;)
Provide the instruction about the contents of
construction document, and the scope of material
● supply and work by vendor, since the scope of
supply and work are sometimes split into several
parties (i.e. several vendors and Toyo).
Engineering Instruction (As necessary;)
Discussed and confirm the necessity of the PWHT
●
procedure for Cr-Mo steel at site, in order to avoid
applying the higher temperature for site PWHT
than the one for tempering by material supplier.
 Security Level 2
GR-TEG1-1000-0004
Appendix(2)-1/1

xxxx PROJECT
xxxx MTPD xxxxxxxxxxxx PLANT
Doc. No : xxxxxxxxx
ENGINEERING INSTRUCTION TO CONSTRUCTION Job No : xxxxxxxxxxxxx
Rev. No.: 0 Page 1 of 1

OWNER : xxxxxxxxxxxxxxxxxxxxxx

CONTRACTOR : xxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxx

PROJECT TITLE : xxxx PROJECT

LOCATION : xxxxxxxxxxxxxxxxxxxxxx

JOB NO. : xxxxxxxxxxxxxxxxxxxxxx

Sample
REV. NO DATE DESCRIPTION PREP’D CHK’D APP’D AUTH’D

0 03/06/2011 Preliminary Issue XXX XXX XXX

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ENGINEERING GUIDE FOR PROCESS PLANT GR-TEG1-1000-004

TOKYO L JAPAN DESIGN GENERAL HISTORY
TOYO ENGINEERING CORP.
GUIDELINE FOR ENGINEERING INSTRUCTION PAGE 1 OF 1
TO CONSTRUCTION

･ISSUE DATE
REV. ･ISSUE GRADE DESCRIPTION
･AUTHORIZATION
0 AUG.16,'11 (1) Background and Reasons for Establishment
(a) To clearly define the list of Engineering Instruction to Construction.
Newly Established
(2) Department and Author
Engineering Engineering Management Division / T. Osanai,
Management Div.
(3) Consultant
Engineering Management Unit / M. Hamamura, H. Kasai, K. Ishii, I. Fukasawa,
T. Nemura, S. Yamazaki, S. Shouji

GR-TEG1-1000-004r.doc