PLANT/FACILITIES ENGINEERING

Definition and Description of Functions and Responsibilities

Approved by the Board of Directors of the

AFE Foundation

December 1997

Special Supplement To

Plant Engineering Magazine

And

AFE Facilities Engineering Journal

REVISION STATEMENT

The 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 under the direction of the Board of Directors of the AFE Foundation by the following:

Chairman, AIPE Foundation: David L. Millay, CPE, Assistant Director-Operations & Maintenance, University of Delaware

Project Coordinator: Richard Eaton, PE/CPE, CFM, C.A.M., CM, Manager, Environmental Engineering, Hitachi Electronic Devices (U.S.A.), Inc.

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

Reviewers:

Joseph H. Greil, CPE, REA, Corporate Director, Facilities Services &
Manufacturing Support, Shipley Company, LLC

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

J. Bruce Medaris, CPE, Managing Director, Association for Facilities Engineering

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.

AVAILABILITY

Copies of this document are available from:

AFE Foundation

8180 Corporate Park Drive, Suite 305

Cincinnati, OH 45242

(888) 222-0155

It can also be found on the Internet at:

www.afe.org

and

www.planteng.com

PLANT/FACILITIES ENGINEERING

AS DEFINED BY

THE AMERICAN INSTITUTE OF PLANT ENGINEERS FOUNDATION

PREFACE

While 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 the authors 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 of "plant/facilities engineering."

DEFINITION

Plant/facilities engineering is a multidisciplinary field of engineering concerned with the physical 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 to produce 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

* 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 coordinating multidisciplinary engineering activities while interacting with all other elements of the 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 systems

Circuit planning

Power distribution

Illumination

Protective devices

Testing

Instrumentation and control

Electrical machinery

Codes and standards

Mechanical systems

Heating, ventilating, air conditioning, and refrigeration

Pumps, piping, and plumbing

Compressors and compressed air systems

Power transmission

Material handling and storage

Fire protection

Instrumentation and controls

Codes and standards

Civil and structural

Materials specification

Structural design and analysis

Construction practices

Building and life safety codes

Maintenance

Systems reliability

Understanding and interpretation of drawings and specifications

Lubrication

Maintenance programs and management

Preventive and predictive maintenance practices

Maintenance supplies, stores, and inventory management

Buildings and grounds

Housekeeping

Welding and joining

Economics

Industrial equipment specification and selection

Estimating

Budgeting and forecasting

Strategic planning

Energy management

Purchasing

Financial management

Administration and supervision

Organization and manpower planning

Personnel development

Business law

Labor relations

Project administration and management

Record keeping

Environmental, safety, and health management

Noise control

Air quality control

Water quality control

Solid waste handling

Hazardous materials control

Regulations, codes and standards

Life safety, security, and firefighting systems

The plant/facilities engineer must have major knowledge emphasis in mechanical, electrical, civil, and/or architectural 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/her professional 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. Because of 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 project, capital expenditure, legal concern, or enterprise policy decision. If in a multisite structure with a corporate engineering department, the plant/facilities engineer should report directly to the site manager with secondary reporting responsibility to the director of corporate engineering.

General Responsibilities

The 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 and maintenance, building

and grounds maintenance, plant protection and security, equipment

maintenance, environmental, and safety

* Providing engineering consulting services, surveys, and

recommendations to all departments 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 a plant/facilities engineer and engineering department.

Administration

Administrative 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 preparation of 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; and maintenance 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/facilities engineering activities

* Solicitation, preparation, and administration of appropriate contracts

* Planning, coordination, and scheduling of predictive and preventative

maintenance programs for structures, utilities, and equipment

(including production equipment in industrial 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 Design

Engineering, layout, and design activities of the plant/facilities engineering department include:

* Furnishing engineering, designs, specifications, bills of materials,

and cost estimates for construction and major rehabilitation of all

real property and for major projects of installation 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

major maintenance, 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 structural, mechanical, electrical,

utilities, site, environmental, and other construction and engineering

drawings for all facilities

* Evaluation and selection of construction contractors

* Oversight and project management of all construction work and approval

after completion.

Plant/Facilities Protection

Plant/facilities protection operations and activities that may be required of a plant/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 emergency response 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

* 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 determine cause 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 local agencies and the company

* Compliance with all applicable federal, state, and local codes,

statutes, and regulations

* 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

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 systems and backup utilities

* Maintenance of appropriate equipment records and histories

* 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 Concerns

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

* 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 the facility and equipment on site

* Formulation of contingency and emergency response plans and training

of personnel for 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 by federal, 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/facilities engineer 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

all such plans, specifications, and contracts before their award

* Representation of the owner's interests in all relevant contracts

either written or implied, interpretation of the responsibilities of

principal and agent, and evaluation of the performance of engineering

work regulated by contracts and specifications

* Project management and completion of all construction contracts

according to plans and specifications.

Insurance

The 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 to reduced 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 building and maintaining relations with other company departments and outside services. As a primarily service/support organization, the plant/facilities engineering department must coordinate 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 the following: 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, and work 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 the production 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 for problems related to such concerns as

speeds of operation, temperature, voltage, pressures, process control

instrumentation, machine communications, and general efficiency of

machinery.

* The plant/facilities engineering department should work with and

support the production department on the design, installation, and

maintenance of production 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 any building 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 facilities operations to each department.

* The plant/facilities engineering department should work with

accounting concerning records and procedures for maintenance and

operations storerooms and stores inventories.

* The plant/facilities engineering department should conduct periodic

capital asset inventories 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 the plant/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 and purchasing departments. Authority

to purchase in emergency or downtime situations should be given

special attention.

* The plant/facilities engineering department should prepare contracts

and specifications and review with the purchasing department all bids

on equipment, construction, power purchases, or other allied services

in compliance with the company’s 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

* 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 on all 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

cousel 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

resources department in maintaining appropriate training,

certification, and licensing records.

*Management Information Resources

* The plant/facilities engineering department will work closely with the

MIS department on the specification, installation, modification, and

maintenance of wiring, power quality, power protection, security, and

other related support systems, utilities, and equipment.

* The plant/facilities engineering department should have responsibility

for and oversee the installation and maintenance of fire protection,

auxiliary power generation, power quality 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 MIS equipment.

* The plant/facilities engineering department should coordinate with the

MIS department on computer equipment and software that will impact

plant/facilities engineering operations, capabilities, and performance.

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