Checking – What Is Piping

What is Design Checking? Design Checking or checking of design is a process of validating a design and/or a design calculation to ensure that it is error-free and of good quality and is good for engineering and/or fabrication or whatever the end-use of it is. Checking is also a process of value addition in terms of applying good engineering practices, aesthetics, reduction in cost and thereby providing better value to the client. A design checklist is prepared for each important design process to aid in design checking process. Why design checking is required? A quality check in design is required to Ensure that the deliverable (drawing, calc, etc.) is error-free.Ensure that it is in-line with the appropriate design standards and codesEnsure that there is consistency in the design approach and aesthetics across units in the designAscertain optimization with respect to design and cost.Reduce field rework Checking of Design–An Overview What do we check against? Check calculations against applicable codes and standardsCheck design against control documents (P&IDs, Line List, General Arrangement Drawings, vendor drawings, design standards, checklists, etc.)Controlled issues of stress isometricsStatutory norms and regulations, eg. OISD, IBR, etc.Design safety, HSE and constructability factors Minimum Quality Plan for design Checking Follow appropriate color codes for checking.Use appropriate checklists. Signed and dated.Continual review of design/model is a mustList items requiring special attention or independent reviewConduct design safety and constructability reviewsMandatory to conduct inter-squad checks on design documents prior to final check and issueConduct formal stage-wise collaborative design review/model review sessions What do we check for? Deliverable is error-free with respect to the inputs providedEase of fabrication, shipping, and erectionReduction in material and fabrication costs. Value+++Build some flexibility into the design, especially for critical itemsEnsure a consistent design approach for similar pieces of equipment and/or unit area pipingAesthetics Responsibility Matrix for design check Every individual is responsible and accountable for checking his deliverable to ensure quality and error-free design.Every individual checks, signs, dates and then passes on to the next individual.Calculations/drawings received for checking by the next individual, without a sign and date, shall not be entertained/accepted!!!Back-ups of holds and assumptions, if any, are maintained in an orderly manner before the issueA signed and dated checklist, completely filled out is a must for any checked document as this is a quality recordThe ultimate responsibility of quality and correctness lies with the lead as he is the one who enforces teams conformance to quality proceduresChecking is a collaborative effort. Every individual owns and is accountable for an error-free and quality product Why Design Checking Adds Value Owning responsibility and following good practices and procedures results in overall qualityUse of checklists ensures important points needing check are not missing outDesign reviews & inter-squad checks ensure interdisciplinary aspects are addressed in the designSafety and constructability reviews ensure good overall layout, approach, constructability, maintenance, and operabilityIncorporating fabrication/contractor specific details and/or preferences into the design helps in easier and faster fabrication and lesser errorsFacilitates a once-through approach from start to finish thereby saving on time and scheduleMinimizes rework in design and at the field Where do we stand today? Ownership and accountability by individuals missing. “Next person will check”!!!Do not prioritize tasks to ensure project schedules and goals are metWork hard but do not “Work Smart”Perform checking using either incomplete and/or superseded inputsDo not capture design changes and revisions properly. Do not use revision notes.Do not follow proper checking procedures, checklists, colors from initial stages. Keep this aside only for the final IFC check stage. Too late….!Do not check important items/spelling. More focused on irrelevant aspectsDo not clarify checking procedures, standards, guidelines, checklists, etc. in the job notes upfrontDo not obtain early client approval on checking procedures and expectationsDo not have a checking and approval matrix for approval of various deliverablesDo not maintain discipline holds summaryTeam and team leader often not aligned regarding the requirements/expectations on the projectFinal number-crunching during IFC issue period often affects productivity, efficiency and lowers team morale What Needs Improvement? Follow a holistic approach towards checkingApproach and expectations shall be clarified upfront through job notes and induction sessionsObtain client approvals and finalize checklists upfrontPay attention to minor details. Spell check is also importantWork smart, prioritize and be focusedChecklists and proper procedures shall be used religiously – this is mandatoryAlways check against the latest documents to avoid rework.Always start the final check process against a frozen and dated set of documents like P&IDs, LL, etc.Lead to incorporate lessons learned in design into checklists as a process of procedural improvementLead to make expectations known to the team, fix individuals responsibility and enforce accountabilityAssign the right work to the right individualTeam to be told that this is not an individual activity but a team effort. We sail or sink together! Synopsis Effective checking is integral to project successTranslates into quality, cost and schedule advantage. Value+++Checking is an innovative process, find the best approach. One hat does not fit all!We need to challenge a situation to come out as a winner. Think “out of the box”!