whitepaper_plantfacilitiesengineering

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PLANT/FACILITIES ENGINEERING

Definition and Description of Functions and Responsibilities

Approved by the Board of Directors of

The AFE Foundation


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REVISION STATEMENTThe plant/facilities engineering function within the industrial, commercial, institutional,

and business communities represents a field of work that is continuously changing. The

ever-increasing demands placed upon the plant/facilities engineer warrant an ongoing

review of those functions and responsibilities. This review process was conducted underthe direction of the Board of Directors of the AFE Foundation by the following:

Chairman, AFE Foundation: Richard L. Dunn, Editor,Plant Engineering Magazine

Project Coordinator: Norwood G. Woody Nelson, FAFE, Retired, Past President

AFE (AIPE)

Principal Editor: Richard L. Dunn, Editor, Plant Engineering Magazine

Reviewers:

John Blumenshine, PE/CPE, Vice President-Facilities, S & C Electric Co.

ACKNOWLEDGMENT

The original plant engineers code, a 1925-28 project of the Plant Engineers Club of

Boston, was developed by a committee headed by Kenneth D. Hamilton. That work

constituted the source for the 1959 revision by a committee chaired by James T. Snow.The revision became the model for a version created in 1994 by Leon R. Martin, CPE,

and Theodore D. Malloy, CPE. The current document, modeled on the previous versions,

but substantially revised, was approved in December 1997 and subsequently updated inDecember, 2002.

AVAILABILITYCopies of this document are available from:

The AFE Foundation

12801 Worldgate Drive Suite 500Herndon, Virginia 20170


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PLANT/FACILITIES ENGINEERING

AS DEFINED BY

THE AFE FOUNDATION

PREFACEWhile many functions and responsibilities within plant/facilities engineering are nearly

universal, there are substantial differences from industrial to commercial to institutional,

and other businesses. This document intends to embrace all of those differences, but theauthors recognize that it can be neither completely inclusive nor exclusive.

Both the names plant engineering and facilities engineering are in widespread use.

And while some may prefer the nuances of one name over another, they are for all

practical purposes interchangeable; thus, the usage throughout this document ofplant/facilities engineering.

DEFINITIONPlant/facilities engineering is a multidisciplinary field of engineering concerned with thephysical infrastructure of industrial, commercial, institutional, healthcare, and business

facilities. It embraces the design, installation, operation, maintenance, modification,

construction, modernization, and protection of physical facilities and equipment used toproduce a product or provide a service. It includes, but is not necessarily limited to, the

following areas of management:

Design of facilities and systems Construction of facilities and systems

Installation of facilities and systems

Start up of systems

Operation of systems Maintenance of facilities and systems

Retrofit of facilities and systems

Environmental controls Safety and health

Security and fire protection

Production processes and equipment (in industry) Regulatory compliance (local, state, and federal)

Energy management and building control

. Energy supplies & contracts in a deregulated market Administration, supervision, organization, planning Other support functions as required by the facility owner or manager.

KNOWLEDGE BASE

Individuals in plant/facilities engineering must continually demonstrate professional

competency in assuming liaison or control responsibility for coordinatingmultidisciplinary engineering activities while interacting with all other elements of the


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organization. The complexity of the plant/facilities engineer position is such that no

single engineering science comprises all its needs.

The practice of plant/facilities engineering at a professional level in its full range of duties requires the

individual to have an understanding of, and proficiency in, the following subject areas:

Electrical systemsCircuit planning

Power distributionIllumination

Protective devices

TestingInstrumentation and control

Electrical machinery

On-site power & co-generation

Codes and standards

Mechanical systemsHeating, ventilating, air conditioning, and refrigerationSteam/water/sewer & process piping

Pumps, piping, and plumbing

Compressors and compressed air systemsPower transmission

Material handling and storage

Fire protectionInstrumentation and controls

Codes and standards

Civil and structural

Drainage & stormwater management

Materials specificationStructural design and analysis

Construction practices

Building and life safety codes

MaintenanceSystems reliability

Understanding and interpretation of drawings and specificationsLubrication

Maintenance programs and management

Preventive and predictive maintenance practicesMaintenance supplies, stores, and inventory management

Buildings and grounds

Housekeeping

Welding and joining

Economics


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Industrial equipment specification and selection

EstimatingBudgeting and forecasting

Strategic planning

Energy management

PurchasingFinancial management

Administration and supervisionOrganization and manpower planning

Personnel development

Business lawLabor relations

Project administration and management

Security services

Record keeping

Environmental, safety, and health managementNoise controlAir quality control

Water quality control

Solid waste handlingHazardous materials control

Regulations, codes and standards

Life safety, security, and fire fighting systems

The plant/facilities engineer must have major knowledge emphasis in mechanical, electrical, civil, and/orarchitectural engineering skills. A basic general knowledge of the remaining engineering sciences is a

necessity for a solid educational base to build on.

The plant/facilities engineer must continue to gain education to forward his/herprofessional knowledge and strengthen the company in which he/she is employed

through continuing formal and informal education, seminars, conferences, and other

sources.

GENERAL DESCRIPTION OF

FUNCTIONS AND

RESPONSIBILITIES

The plant/facilities engineering department in any enterprise is multifunctional. Becauseof this diversity, the reporting procedure and the direct responsibilities should be clearly

defined.

Reporting

The plant/facilities engineering director should report directly to the general manager,

unit manager, president, CEO, owner, or whoever makes the final decision on any


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project, capital expenditure, legal concern, or enterprise policy decision. If in a multisite

structure with a corporate engineering department, the plant/facilities engineer shouldreport directly to the site manager with secondary reporting responsibility to the director

of corporate engineering.

General ResponsibilitiesThe plant/facilities engineering manager should be responsible for:

Directing and coordinating the operations and activities of plant/facilities engineering

administration, engineering, layout, design, construction, utilities operations andmaintenance, building and grounds maintenance, plant protection and security,

equipment maintenance, environmental, and safety

Providing engineering consulting services, surveys, and recommendations to alldepartments of the complex; to outside architect-engineer firms performing services

for the complex; and to public utilities

Ensuring compliance with applicable federal, state, and local laws, regulations,

statutes, and codes; securing all required permits; and coordinating with appropriate

local authorities Contracting with and overseeing the activities of various contractors and consultants

for the fulfillment of plant/facilities engineering responsibilities.

FUNCTIONS OF THE PLANT/FACILITIES ENGINEERING DEPARTMENT

Every company, business, or corporation has created its own distinct responsibility

assignments for each department. The following outline is intended to help define and

understand the specific functions, operations, and activities that may be required of aplant/facilities engineer and engineering department.

AdministrationAdministrative operations of the plant/facilities engineering department include:

Program coordination for the plant/facilities engineering department and liaison with

all other departments for the procurement and maintenance of all real property,production equipment, utilities services, and communications services

Preparation of plant/facilities engineering department budgets

Proposal, justification, and management of capital projects and expenditures Maintenance of records of planned and current construction and maintenance

contracts

Review and filing of reports from inspectors and insurance carriers, and preparationof status reports to appropriate management

Processing of work requests; preparation of project cost estimates; planning and

scheduling of work; provision of required parts, materials, and equipment; andmaintenance of all related labor and equipment records

Management of parts, materials, and equipment for which the plant/facilities

engineering department is held accountable

Preparation of appropriate reports, statistics, and recommendations on plant/facilitiesengineering activities

Solicitation, preparation, and administration of appropriate contracts


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Planning, coordination, and scheduling of predictive and preventative maintenance

programs for structures, utilities, and equipment (including production equipment inindustrial plants)

Maintenance of appropriate records pertaining to labor under the jurisdiction of the

plant/facilities engineering department

Assuring that department personnel are licensed, registered, or certified as appropriate.

Engineering, Layout, and DesignEngineering, layout, and design activities of the plant/facilities engineering departmentinclude:

Furnishing engineering, designs, specifications, bills of materials, and cost estimates

for construction and major rehabilitation of all real property and for major projects ofinstallation and relocation of equipment

Continual review and evaluation of utility, building, and structural requirements and

preparation of projects as required

Acting as technical liaison for design engineering projects of collateral interest with

other departments Maintaining a master plan for improvement and expansion of the plant/facilities

Preparation of designs, layouts, drawings, and bills of materials for majormaintenance, plant/facility improvement, and other projects

Maintenance of current as built drawings and files for all plant/facility structures,

systems, equipment, etc. Provision of technical/engineering support to other departments regarding process

and/or equipment changes

Maintenance of all real property records.

Construction

Plant/facilities construction operations and activities that may be required of a

plant/facilities engineer and engineering department include:

Preparation or oversight of the architectural, structural, mechanical, electrical,

utilities, site, environmental design, and other construction and engineering drawingsfor all facilities

Evaluation and selection of construction contractors

Oversight and project management of all construction work and approval after completion.

Plant/Facilities ProtectionPlant/facilities protection operations and activities that may be required of aplant/facilities engineer and engineering department include:

Training of designated plant personnel in fire fighting and emergency response.

Training of personnel in all phases of operation and maintenance of emergencyresponse apparatus and fire extinguishing systems. Conduct of emergency evacuation

drills

Regularly inspecting buildings, fire fighting equipment, fire protection systems, and

areas to detect and eliminate fire, safety, health and security hazards Assuring compliance with all applicable life safety and building codes and

regulations


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Design, installation, and maintenance of all plant/facility fire protection and security

systems Specification, installation, and maintenance of all fire protection and security

equipment

Formulation of all emergency response and recovery plans for all areas of the plant or

enterprise Provision of first-response capability for all life-threatening and property-threatening

emergencies

Providing assistance in investigation of fires and other emergencies to determinecause and take corrective/preventive action

Maintaining liaison with local community emergency-response and law-enforcement

organizations for assistance as required Maintenance of all required records for OSHA and other regulatory agencies

Establishment of practices regarding handling and disposal of classified materials

Conduct of necessary security checks, inspections, surveys and investigations to

assure that the required standards of physical security are maintained.

Establishment and operation of employee and visitor control identification systems. Control of security cards and keys for buildings, structures and equipment;

maintenance of vaults, safes, and locked files.

Utilities Operation & Energy Management

Utilities operations and energy management responsibilities that may be required of a plant/facilities

engineer and engineering department include: Operation and maintenance of all utilities systems and equipment in the

plant/complex

Completion of operating logs, reports, and records required by federal, state, and localagencies and the company

Compliance with all applicable federal, state, and local codes, statutes, andregulations

Development of energy management and conservation programs

Liaison with public utilities

Procurement of fuels and energy Specifying, operating, and maintaining of backup utility systems.

Maintenance Management

The maintenance operations and activities that may be required of a plant/facilities

engineer and engineering department include:

Installation and maintenance of all utilities systems and components for electricity,water, steam, gas, oil, compressed air, communications, data networks, etc.

Provision of services for construction, alterations, maintenance, and repair of

buildings and structures Installation, operation, and maintenance of all heating, ventilating, air conditioning,

and refrigeration systems and components

Installation, relocation, modification, maintenance, and repair other equipment and

systems as determined by coordination with other departments Testing of electrical & utility back-up systems

Maintenance of appropriate equipment records and histories


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Management of maintenance planning, scheduling, and work execution

Implementation of preventive and predictive maintenance strategies and practices Management of spare parts and materials storerooms and inventories

Coordination of federal, state, local, and insurance licensing inspections and compliance

Management of special projects as required

Provision of housekeeping, janitorial, and custodial services

Environmental Stewardship

The environmentally related operations and activities that may be required of aplant/facilities engineer and engineering department include:

. Champion waste minimization efforts throughout operations

Initiation of all requests for air quality, water quality, stormwater discharge,hazardous material, and solid waste disposal permits pertaining to the facility and all

equipment contained within it to meet federal, state, and local requirements

Coordination and supervision of all monitoring required to meet federal, state, and

local regulations

Maintenance of all environmental permits and recordkeeping required to operate thefacility and equipment on site

Formulation of contingency and emergency response plans and training of personnelfor control, containment, cleanup, and disposal of hazardous and nonhazardous spills

Management of environmental monitoring activities

Correction of environmental deficiencies Notification of appropriate regulatory agency representatives of any and all occurrences that deviate

from compliance guidelines and laws.

Safety

The safety operations and activities that may be required of a plant/facilities engineer and

engineering department include: Organization, administration, and supervision of safety activities in accordance with

all federal, state, and local requirements

Instruction and training of employees in safety requirements and procedures for the

facility, its equipment and systems Conduct of regular periodic safety inspections of buildings, grounds, production equipment, utilities

equipment and services, etc.

Maintenance of records of training and inspections pertaining to safety as required byfederal, state, and local authorities

Initiation of safety-related work requests

Compliance with all safety procedures.

Contracts

The contracting operations and activities that may be required of a plant/facilitiesengineer and engineering department include:

Review and approval of all bids and submissions for plant/facilities contract work

Preparation, in coordination with legal counsel, of all major contracts for engineering work, technical

specifications, purchase of equipment, and the erection and maintenance of structures; approval of allsuch plans, specifications, and contracts before their award


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Representation of the owners interests in all relevant contracts either written or

implied, interpretation of the responsibilities of principal and agent, and evaluation ofthe performance of engineering work regulated by contracts and specifications

Project management and completion of all construction contracts according to plans

and specifications.

InsuranceThe insurance operations and activities that may be required of a plant/facilities engineer

and engineering department include:

Working with insurers on engineering problems, inspections, and corrections toreduced hazards and rates.

Conduct of periodic inspections of the plant to cover all departments to maintain a

recommendation-free environment. Maintaining appropriate knowledge of rules and regulations of insurers

Coordination of construction and other projects with insurance carriers.

RELATIONS WITH OTHER DEPARTMENTS AND SERVICES

A major activity of the plant/facilities engineer and engineering department is buildingand maintaining relations with other company departments and outside services. As a

primarily service/support organization, the plant/facilities engineering department mustcoordinate with and respond to the needs of other departments. The following outline

provides guidance on the organizational relationships between the plant/facilities

engineering department and other departments and services.

Plant/Facility and Company Management The plant/facilities engineering department should ensure that plant/company

management is kept thoroughly informed on all matters that are the responsibility of

the plant/facilities engineering department, especially matters concerning thefollowing: value of assets, insurance, environmental compliance, safety, permits,

regulations, and ability of the plant/facility to produce products or provide services.

The plant/facilities engineering department should report periodically to management

on work accomplished, work in process, status of conditions under its control, andwork anticipated. These reports should include comments and recommendations as

appropriate.

Production Department

The plant/facilities engineering department should not assume responsibility for

production scheduling, quantity, or quality, but it should work closely with theproduction department in supporting production goals.

In liaison with the production department, the plant/facilities engineering department

should provide and maintain equipment for production and be responsible forproblems related to such concerns as speeds of operation, temperature, voltage,

pressures, process control instrumentation, machine communications, and general

up-time and efficiency of machinery.

The plant/facilities engineering department should work with and support theproduction department on the design, installation, and maintenance of production


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systems and equipment and should advise on the safe and economical operation of

such equipment. As part of its overall responsibility for plant and equipment maintenance, the

plant/facilities engineering department should work with production personnel on

maintenance training, scheduling, and procedures for production equipment

Accounting Department The plant/facilities engineering department should coordinate with the accounting

department for establishing appropriate accounts for such classifications as the plant/facilities

engineering department may require. The plant/facilities engineering department should define the classification of any

labor or materials used on any work performed under its supervision.

The plant/facilities engineering department should be consulted as to life of anybuilding or equipment in connection with depreciation evaluation.

The plant/facilities engineering department should approve all payments to

contractors and contract engineers for work done under its auspices.

The accounting department and the plant/facilities engineering department will

cooperate in the preparation of figures for the distribution of expenses for facilitiesoperations to each department.

The plant/facilities engineering department should work with accounting concerningrecords and procedures for maintenance and operations storerooms and stores

inventories.

The plant/facilities engineering department should conduct periodic capital assetinventories for accounting purposes.

Purchasing Department

The plant/facilities engineering department should generate all specifications for, and

approve all materials and equipment furnished in response to, its requisitions. Major or specialized equipment should be specified and selected by the

plant/facilities engineering department in cooperation with purchasing, production, or

other involved departments.

Information regarding relevant suppliers and sources should be shared between theplant/facilities engineering and purchasing departments.

Purchasing policies concerning authority to specify products, materials, sourcing, etc.,

should be worked out cooperatively between the plant/facilities engineering andpurchasing departments. Authority to purchase in emergency or downtime situations

should be given special attention.

The plant/facilities engineering department should prepare contracts andspecifications and review with the purchasing department all bids on equipment,

construction, power purchases, or other allied services in compliance with the

companys internal audit regulations. The plant/facilities engineering department will check and report all goods received

on its orders for quantity and quality, and should make such tests as are necessary and

report to the purchasing department when requested as to the results obtained.

Consultants


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The plant/facilities engineering department should have authority to contract with consultants when

additional professional or technical advice is necessary or appropriate. All plant/facilities engineering data furnished to consultants should be provided by or

approved by the plant/facilities engineering department.

Any plant/facilities engineering work done by a consultant should be subject to the review and

approval of the plant/facilities engineer.

Legal Counsel

The plant/facilities engineering department should obtain the advice of legal counsel

on all special problems pertaining to law.

The plant/facilities engineering department should coordinate with legal counsel onall matters pertaining to land, water, and air rights.

The plant/facilities engineering department should inform legal counsel of all issues

relating to usage, storage, and disposal of hazardous and controlled substances.

The plant/facilities engineering department should coordinate with legal counsel

concerning intellectual property rights under its jurisdiction. The plant/facilities engineering department should consult with legal counsel on all

code, environmental, safety, and other regulatory demands or visits.

Human Resources The plant/facilities engineer should work with the human resources department in

preparing hiring, testing, and training guidelines and requirements for employees in

the plant/facilities engineering department.

The plant/facilities engineering department should work with the human resourcesdepartment in maintaining appropriate training, certification, and licensing records.

Management Information Resources The plant/facilities engineering department will work closely with the IS department

on the specification, installation, modification, and maintenance of wiring, power

quality, power protection, security, and other related support systems, utilities, andequipment.

The plant/facilities engineering department should have responsibility for and oversee

the installation and maintenance of fire protection, auxiliary power generation, powerquality equipment, power protection equipment, construction, controlled

environments, routing, wiring, and fiber optic installation to termination points, in

new and existing structures. The plant/facilities engineering department should ensure the continued service of all

required utilities at specified conditions to allow proper operation of IS equipment.

The plant/facilities engineering department should coordinate with the IS departmenton computer equipment and software that will impact plant/facilities engineering

operations, capabilities, and performance.

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