Front End Engineering Design: FEL 1, 2, and 3 deliverables.

In the complex and highly regulated world of chemical, oil & gas, and petrochemical plant development, Front End Engineering Design (FEL) plays a critical role in laying the foundation for project success. This multi-phased process involves progressively refining the project scope, definition, and feasibility, ultimately paving the way for detailed engineering and construction.

What is FEL?

FEL, also known as Front-End Loading, is a structured approach to project development divided into three distinct stages: FEL 1, FEL 2, and FEL 3. Each stage delivers progressively more detailed information and serves as a decision-making point for project stakeholders.

FEL 1: Feasibility Study

The cornerstone of any project, FEL 1 focuses on establishing project feasibility and providing a high-level overview of its technical and economic viability. This stage typically involves:

Deliverables:

• ·     Preliminary Process Design: Defining the key process steps, flow diagrams, and mass and energy balances.
• ·     Plant Layout: Developing a conceptual site layout and equipment arrangement.
• ·     Equipment List: Identifying the major equipment required for the project.
• ·     Cost Estimate: Estimating the project’s capital and operating costs.
• ·     Project Schedule: Creating a preliminary timeline for project execution.
• ·     Preliminary Risk Assessment: Identifying potential risks and mitigation strategies.

 

FEL 2: Pre-FEED Study, sometimes called basic engineering

Building upon the foundation established in FEL 1, FEL 2 delves deeper into defining the project scope and technical specifications. This stage typically includes:

·       Deliverables:

• Process Flow Diagrams and Instrumentation (PFDs & P&IDs): Creating detailed process diagrams and specifying instrumentation requirements.
• Process Simulation: Refining the process design using sophisticated simulation software.
• Equipment Specifications: Developing detailed specifications for major and minor equipment.
• Piping Design: Completing a preliminary piping layout and estimating materials.
• Civil and Structural Design: Developing preliminary designs for civil and structural elements.
• Electrical and Instrumentation Design: Refining the electrical and instrumentation systems design.
• Cost Estimate: Updating the cost estimate with greater accuracy.
• Project Schedule: Refining the project schedule with a more realistic timeline.
• Risk Assessment: Conducting a more in-depth risk assessment and developing mitigation plans.

 

FEL 3: FEED Study, sometimes called basic engineering

·       FEL 3 represents the final and most comprehensive stage of the FEL process. It focuses on finalizing the project design and preparing a comprehensive set of documents for bidding and construction. This stage typically includes:

·       Deliverables:

• Process Design Package: Finalizing all process-related drawings, specifications, and data sheets.
• Piping Design Package: Completing all piping drawings, specifications, and isometric drawings.
• Civil and Structural Design Package: Finalizing all civil and structural drawings and specifications.
• Electrical and Instrumentation Design Package: Finalizing all electrical and instrumentation drawings and specifications.
• Material Take-Off: Listing all materials required for construction.
• Bid Package Preparation: Developing a comprehensive bid package for contractors.
• Cost Estimate: Refining the cost estimate with a high degree of accuracy.
• Project Schedule: Finalizing the project schedule with a detailed breakdown of activities.

It is crucial to understand the criticality of each FEL stage and possess extensive experience in delivering high-quality deliverables that meet industry standards and client expectations.

 

What is next?

 

What Is Detailed Engineering?

Detailed engineering is the phase that follows FEL-3 and the formal investment decision. It’s where the project moves from planning into execution readiness. At this point, the scope is locked, the business case is approved, and the focus shifts to producing all the technical documentation needed to build, install, and operate the asset.

Unlike FEL stages, which are about evaluating and defining the project, detailed engineering is about specifying exactly how it will be built.

 

Typical Deliverables of Detailed Engineering

Here’s what you can expect to be delivered during detailed engineering:

1. Final Design Documents

• Plot plan
• 3D model 90+%
• Complete P&IDs (Piping and Instrumentation Diagrams)
• Process flow diagrams (PFDs)
• General arrangement drawings
• Equipment specifications and datasheets
• Electrical single-line diagrams
• Instrumentation and control system designs
• Operational, Maintenance detailed reviews

2. Procurement Packages

• Bill of materials (BOM)
• Vendor specifications and datasheets
• RFQs (Request for Quotations)
• Technical bid evaluations
• Negotiations with selected vendors
• Purchase orders for long-lead items

3. Construction Documentation

• Isometric drawings for piping
• Structural and civil drawings
• Installation details
• Construction work packages
• Site layout and logistics plans

4. Compliance and Safety

• HAZOP and safety reviews
• Environmental and permitting documentation
• QA/QC plans
• Regulatory compliance documentation

5. Project Execution Support

• Updated cost and schedule baselines
• Construction sequencing plans
• Pre-commissioning
• Punching system
• Training materials for operations and maintenance
• Train Operations
• Commissioning and startup procedures

 

Why It Matters

Detailed engineering is critical because it:

• Eliminates ambiguity before construction begins
• Reduces change orders and delays
• Ensures compliance with safety and regulatory standards
• Provides the foundation for procurement, construction, and commissioning