What is FEED (Front-end Engineering Design) in Projects?

In the world of engineering projects, particularly in sectors like oil and gas, renewable energy, and infrastructure development, the term FEED holds significant importance. FEED, which stands for Front-end Engineering Design, represents a crucial phase in the project lifecycle that lays the groundwork for successful project execution.

Front-end engineering and design (FEED) is super important for getting projects ready to rock! It’s not just about guessing how much a project will cost. FEED involves planning out every detail of the project, like what needs to be done, how much it’ll cost from start to finish, how long it’ll take, and what could go wrong.

By figuring out all these things upfront, FEED helps reducing on surprises and problems later on when the project is being built and tested. It’s like making a solid plan before building a house, you want to know everything from the size of the rooms to the color of the paint before you start hammering nails. Doing FEED right can save time and money and make sure the project runs smoothly from beginning to end.

FEED is essentially a preliminary engineering phase that occurs after the conceptual design or feasibility study of a project. During this stage, engineers and designers develop a detailed understanding of project requirements, constraints, and objectives. The primary goal of FEED is to define the project scope, establish technical specifications, and evaluate various design options to identify the most feasible and cost-effective solution.

Below picture shows phases of engineering project in plant, oil and gas etc.

What is the Deliverable from a FEED?

The Front-end Engineering Design (FEED) phase is crucial in setting the stage for project success. While each project may have its unique requirements, there are typical deliverables that includes in its FEED process. Following we summarize design deliverables:

1. Requirements Specifications: Clearly defined project requirements detailing what needs to be achieved.
2. Package Specifications: Specifications for various equipment packages needed for the project.
3. MCC, Panel Designs: Designs for Motor Control Centers (MCC) and electrical control panels.
4. Advanced Control and Optimization Specifications: Specifications for advanced control systems and optimization strategies.
5. Migration Strategy: Strategy for migrating existing systems or processes to new ones.
6. PFD, P&ID Electrical Diagrams: Process Flow Diagrams (PFD) and Piping & Instrumentation Diagrams (P&ID) for electrical systems.
7. Equipment General Arrangements: Layout plans and arrangements for equipment.
8. Utility Loads: Calculation and specification of utility requirements.
9. HAZID Reports: Reports identifying and assessing potential hazards.
10. Basis of Design: Document outlining the basis for the project’s design decisions.
11. Lists (Equipment, Instrument, Motor, I/O): Comprehensive lists of equipment, instruments, motors, and input/output requirements.
12. Control Narratives: Descriptions detailing control strategies and functionalities.
13. Control, Safety, and Operational Procedures: Procedures for control, safety, and operational aspects of the project.
14. Network Architectures: Architectural plans for project networks.
15. Validation Strategy: Strategy for validating project requirements and deliverables.

These deliverables serve as the foundation for further project planning and execution. They are used to generate:

• Overall Project Cost Estimate, ROI Justification, and Procurement Scenarios: Estimates of project costs, Return on Investment (ROI) justifications, and scenarios for procurement planning.
• Project Schedule / Gantt Chart: A detailed timeline outlining project activities and milestones.

By providing these comprehensive deliverables, the FEED phase ensures that project stakeholders have a clear understanding of project requirements, design specifications, and implementation plans, setting the stage for a successful project execution.

Process Deliverable from a FEED.

1. Generation of Process Flow Diagrams (PFD) and P&IDs: Creating visual representations of the process flow and the instrumentation used to control it.
2. Process Modeling: Using software tools to simulate and analyze the process behavior under different conditions.
3. Technical Specification and Basis of Design Development: Developing detailed technical specifications and outlining the fundamental principles guiding the project’s design decisions.
4. Equipment Specification and Sizing: Selecting and sizing the equipment needed for the process based on its requirements.
5. Safety Device Sizing and Selection: Determining the appropriate size and type of safety devices (such as relief valves) to protect the process from overpressure or other hazardous conditions.
6. Full Hydraulic Calculations: Performing calculations to ensure that hydraulic systems operate effectively and safely.
7. PFD Review, Estimate, and Report of Process Performance with MPC System: Reviewing the Process Flow Diagram, estimating the project’s cost, and reporting on how the process will perform with a Model Predictive Control (MPC) system in place.

These tasks are essential for designing and optimizing the process, ensuring its safety, efficiency, and effectiveness.

Mechanical Engineering Deliverable from a FEED.

Following is mechanical tasks list related to FEED (Front-end Engineering Design):

1. Development of Modular Process Solutions: Creating standardized, pre-fabricated components or systems that can be easily assembled and integrated into the overall project design, helping to streamline construction and reduce costs.
2. Layouts: Planning the spatial arrangement of equipment and infrastructure within the project site to optimize efficiency, accessibility, and safety. This includes determining the best placement of machinery, piping, and other components.
3. Process and Utility Piping Systems: Designing the network of pipes that will transport materials and utilities (such as water, steam, and gases) throughout the project. This involves specifying pipe sizes, materials, routes, and connections to ensure proper flow and functionality.
4. Including Hygienic Processes: Implementing specialized processes and equipment designs to maintain strict hygiene standards, particularly in industries like food, pharmaceuticals, and biotechnology. This may involve selecting materials and equipment that are easy to clean and sterilize, as well as incorporating features to prevent contamination.

Electrical & Power Engineering Deliverable from a FEED.

Following is Electrical & Power tasks list related to FEED (Front-end Engineering Design):

1. Power System Load Studies: Analyzing and calculating the electrical load requirements for the project to ensure that the power system can handle the expected demand safely and efficiently.
2. Electrical Design Diagrams: Creating detailed diagrams and schematics that illustrate the layout and configuration of electrical systems, including distribution networks, control panels, and wiring connections.
3. Electrical Load List: Compiling a comprehensive list of all electrical loads within the project, specifying the power requirements for each piece of equipment or system.
4. Equipment Specifications & Design (LV/MV Switchgear, MCC, etc.): Selecting and designing the appropriate electrical equipment for the project, such as Low Voltage (LV) and Medium Voltage (MV) switchgear, Motor Control Centers (MCC), transformers, and other components.
5. Electrical Heat Trace: Designing and implementing electrical heat tracing systems to prevent freezing or maintain temperature control in pipes, tanks, and other critical equipment.
6. Cable Sizing: Calculating the appropriate size and type of electrical cables needed to safely and efficiently transmit power throughout the project, taking into account factors such as voltage, current, distance, and environmental conditions.

These power/electrical tasks are essential for ensuring the reliability, safety, and efficiency of the project’s electrical systems. They lay the groundwork for detailed engineering and construction activities, helping to minimize risks and optimize performance during the project lifecycle.

Control System & Network Deliverable from a FEED.

Following is Control System & Network tasks list related to FEED (Front-end Engineering Design):

1. Preparation of System Architecture: Developing the overall structure and layout of the control systems, including the arrangement of controllers, sensors, actuators, and communication networks.
2. Preparation of Operation and Control Philosophy: Defining the principles and strategies that will guide the operation and control of the project, including modes of operation, control strategies, and emergency procedures.
3. Preparation of Control Narratives: Documenting detailed descriptions of the control strategies and functionalities for each part of the project, outlining how different systems will be monitored, controlled, and managed.
4. Advanced Process Control Reviews: Evaluating and optimizing advanced control systems and algorithms to improve process performance, efficiency, and stability.
5. Hardware Specifications: Specifying the hardware requirements for the control systems, including controllers, interfaces, sensors, and actuators, ensuring compatibility and reliability.
6. I/O Lists, Drawings: Compiling comprehensive lists of inputs and outputs for the control systems, as well as creating detailed drawings and schematics that illustrate the connections and interfaces between different components.
7. Installed Base Assessment and Obsolescence Study: Assessing the existing control systems and equipment to identify any outdated or obsolete components that may need to be upgraded or replaced.
8. Network Design, Security Assessment: Designing the communication networks that will connect the various control systems and devices, as well as assessing and implementing security measures to protect against cyber threats and unauthorized access.
9. IT Infrastructure Assessment: Evaluating the existing IT infrastructure and systems that support the project, including servers, databases, and software applications, to ensure compatibility and reliability.

Safety Engineering Deliverable from a FEED.

Following is Safety engineering tasks list related to FEED (Front-end Engineering Design):

1. Hot Safety System Migration Strategies: Planning strategies for migrating safety systems while the process is still operational, ensuring safety is maintained during the transition.
2. Risk Analysis, HAZID Studies: Assessing potential risks and hazards associated with the project through Hazard Identification (HAZID) studies and risk analysis techniques to mitigate risks and enhance safety.
3. Safety System Design and Documentation: Designing and documenting safety systems, including emergency shutdown systems, fire protection systems, and other safety measures to protect personnel, equipment, and the environment.
4. Preparation of Safety Philosophy / Narratives: Defining the principles, strategies, and procedures that govern safety management and operations, outlining how safety will be integrated into all aspects of the project.
5. SIL Target Determination and Analysis: Determining Safety Integrity Level (SIL) targets for safety instrumented systems (SIS) and conducting analysis to ensure that these systems meet the required safety standards and performance criteria.
6. ATEX (Hazardous Area Classification Compliance): Ensuring compliance with ATEX directives by classifying hazardous areas and implementing measures to prevent the ignition of explosive atmospheres.
7. Machine Safety Assessments: Assessing the safety of machinery and equipment to identify and mitigate potential hazards, ensuring compliance with safety standards and regulations to protect workers from harm.

Quality System Deliverable from a FEED.

Following is Quality engineering tasks list related to FEED (Front-end Engineering Design):

1. GMP Risk Assessment: Conducting a risk assessment based on Good Manufacturing Practice (GMP) guidelines to identify potential quality risks and ensure compliance with regulatory standards in industries such as pharmaceuticals and biotechnology.
2. Gap Analysis vs Current Regulation Study: Comparing the project’s current practices and processes against relevant regulations and standards to identify any gaps or areas of non-compliance and develop strategies for addressing them.
3. Quality Documentation (Quality Plan, Validation Master Plan, etc.): Developing comprehensive documentation outlining the quality management processes, procedures, and protocols for the project. This may include a Quality Plan detailing quality objectives, responsibilities, and procedures, as well as a Validation Master Plan outlining the validation approach for systems, equipment, and processes to ensure they meet regulatory requirements and quality standards.

Instrumentation Deliverable from a FEED.

Following is instrumentation engineering tasks list related to FEED (Front-end Engineering Design):

1. Instrument Specifications and Selection: Defining the requirements and selecting the appropriate instruments for measuring and controlling process variables such as temperature, pressure, flow, and level.
2. Preparation of Instrument Indexes and I/O Lists: Compiling comprehensive lists of all instruments used in the project, along with their input/output (I/O) requirements, to ensure proper integration and communication with control systems.
3. Preparation of Instrument Data Sheets: Creating detailed specifications for each instrument, including technical specifications, performance requirements, and installation details, to guide procurement and installation activities.
4. Cable Block Diagrams: Developing diagrams that illustrate the connections and routing of cables between instruments, control systems, and other components, ensuring proper wiring and communication throughout the project.
5. P&ID Review of Instruments Required for Unit or Plant-wide Model Predictive Control (MPC): Reviewing Process and Instrumentation Diagrams (P&IDs) to identify the instruments needed for implementing Model Predictive Control (MPC) systems at unit or plant-wide levels, optimizing process performance and efficiency.
6. Gap Analysis Report on Optimization Instruments: Conducting an analysis to identify any gaps or deficiencies in the instrumentation related to process optimization, such as missing sensors or control loops, and proposing solutions to enhance performance and efficiency.

Information (MES/MIS) Deliverable from a FEED.

Following is Information (MES/MIS) tasks list related to FEED (Front-end Engineering Design):

1. Installed Base Assessment: Evaluating the existing information systems, including Manufacturing Execution Systems (MES) or Management Information Systems (MIS), to understand the current capabilities, limitations, and infrastructure.
2. Preparation of Requirements and/or Upgrade Specifications: Identifying and documenting the functional requirements and specifications for MES/MIS systems, including any necessary upgrades or enhancements to meet project objectives and user needs.
3. Line Integration, Line Performance: Integrating MES/MIS systems with production lines and equipment to streamline operations, improve efficiency, and optimize line performance. This involves monitoring and analyzing key performance indicators (KPIs) to identify areas for improvement and implement corrective actions.
4. Plant / Multi-site Reporting, KPI Dashboards, Web-forms, Analytics: Developing reporting tools, dashboards, and web-based forms to facilitate data collection, analysis, and reporting across multiple plant sites or production lines. This includes creating Key Performance Indicator (KPI) dashboards to track and visualize performance metrics, as well as implementing analytics tools to gain insights from production data.

Packaged Equipment Deliverable from a FEED.

Following is Packaged Equipment Engineering tasks list related to FEED (Front-end Engineering Design):

1. Site-wide Standards and Specifications for Packaged Equipment: Developing standardized guidelines and specifications for selecting, procuring, and installing packaged equipment across the project site. This ensures consistency, efficiency, and compatibility with existing infrastructure.
2. Package Equipment Upgrade Specifications: Identifying and documenting specific requirements for upgrading or replacing existing packaged equipment to improve performance, reliability, or compliance with regulatory standards. This may include specifying technical specifications, performance criteria, and integration requirements.
3. Packaged Equipment Integration: Integrating packaged equipment into the overall project design and infrastructure, ensuring seamless operation and compatibility with other systems and components. This involves coordinating installation, wiring, and communication protocols to optimize performance and minimize downtime.

Components of FEED:

1. Scope Definition: One of the primary tasks during FEED is to clearly define the scope of the project. This involves identifying project objectives, deliverables, key milestones, and any specific requirements outlined by the client or stakeholders.
2. Engineering Design: During FEED, engineering teams delve into the detailed design of various project components, including process systems, equipment layout, piping and instrumentation diagrams (P&IDs), structural design, electrical systems, and instrumentation.
3. Cost Estimation: Accurate cost estimation is crucial for project planning and budgeting. Engineers work on developing detailed cost estimates based on the proposed design, material quantities, labor requirements, and other factors.
4. Risk Assessment: Identifying and mitigating potential risks is essential to ensure project success. FEED includes a thorough risk assessment process to anticipate and address technical, environmental, regulatory, and operational risks that could impact the project.
5. Regulatory Compliance: Compliance with applicable regulations and standards is paramount in engineering projects. Engineers ensure that the proposed design meets all relevant regulatory requirements and industry standards.
6. Procurement Strategy: FEED also involves developing a procurement strategy for sourcing materials, equipment, and services required for the project. This includes identifying potential suppliers, evaluating bids, and establishing procurement timelines.

Importance of FEED:

1. Risk Mitigation: By conducting a comprehensive engineering analysis during the FEED phase, potential risks and challenges can be identified early on, allowing for proactive mitigation measures to be implemented.
2. Cost Savings: Investing in thorough engineering design and planning during FEED helps prevent costly changes and delays during later stages of the project. It enables more accurate cost estimation and budgeting, ultimately leading to cost savings.
3. Optimized Design: FEED allows engineers to evaluate various design options and select the most optimal solution based on technical feasibility, performance criteria, and economic considerations.
4. Enhanced Project Schedule: A well-defined scope and detailed engineering design developed during FEED facilitate smoother project execution, reducing the likelihood of schedule overruns and delays.
5. Client Satisfaction: Clear communication and alignment of project objectives during the FEED phase contribute to greater client satisfaction by ensuring that the final deliverables meet or exceed expectations.

Conclusion:

In the complex engineering projects, Front-end Engineering Design (FEED) serves as a critical precursor to successful project execution. By meticulously defining project scope, conducting detailed engineering analysis, and addressing potential risks, FEED lays the foundation for cost-effective, efficient, and technically sound project delivery. Embracing the importance of FEED ensures that engineering projects are set up for success from the outset, ultimately leading to improved outcomes and stakeholder satisfaction.