DEP 30.10.05.11-GEN Feb 2012 3D Model Review.

DEP SPECIFICATION

PLANT MODEL CONSTRUCTION AND REVIEW

DEP 30.10.05.11-Gen. February 2012

DESIGN AND ENGINEERING PRACTICE

© 2012 Shell Group of companies All rights reserved. reserved. No part of this publication may be reproduced, reproduced, stored in a retrieval system, system, published published or transmitted, transmitted, in any form or by any means, without without the prior written permission of the copyright owner or Shell Global Solutions International BV.

DEP 30.10.05.11-Gen. February 2012 Page 2

PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies. These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards. The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplierr shall, without detracting from his own responsibility, consult the Principal. Manufacturer/Supplie The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished: 1)

Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.

2)

Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).

3)

Contractors/subcontractors Contractors/subcontrac tors and Manufacturers/Suppliers Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all r espects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative administrative queries should should be directed to the DEP Administrator in Shell Shell GSI.


PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies. These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards. The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplierr shall, without detracting from his own responsibility, consult the Principal. Manufacturer/Supplie The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished: 1)

Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.

2)

Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).

3)

Contractors/subcontractors Contractors/subcontrac tors and Manufacturers/Suppliers Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all r espects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative administrative queries should should be directed to the DEP Administrator in Shell Shell GSI.

DEP 30.10.05.11-Gen. February 2012 Page 3 TABLE OF CONTENTS 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7

INTRODUCTION INTRODUCTION ..................................................................................... ........................................................................................................4 ...................4 SCOPE........................................................................................................................4 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS CONSIDERATIONS .........4 DEFINITIONS ............................................................................................. .............................................................................................................4 ................4 CROSS-REFERENCES CROSS-REFERENCE S .............................................................................................5 SUMMARY OF MAIN CHANGES...............................................................................5 COMMENTS ON THIS DEP DEP ...................................................................................... .......................................................................................5 .5 DUAL UNITS...............................................................................................................6

2.

GENERAL...................................................................................................................7

3 3.1 3.2 3.3 3.4.

MODEL REVIEWS .............................................................................. .....................................................................................................8 .......................8 GENERAL...................................................................................................................8 TOOLS........................................................................................................................8 TEAM COMPOSITION ...............................................................................................9 HANDLING OF COMMENTS .....................................................................................9

4. 4.1 4.2 4.3 4.4 4.5 4.6

3D-CAD MODEL ........................................................................................... ......................................................................................................11 ...........11 GENERAL.................................................................................................................11 SAFETY, OPERATIONAL OPERATIONAL AND MAINTENANCE ASPECTS ASPECTS ..................................11 AT THE CONSTRUCTION SITE ..............................................................................11 INSTRUCTION ........................................................................................... .........................................................................................................12 ..............12 FEATURES WITH 3D-CAD TECHNOLOGY............................................................12 REQUIREMENTS ............................................................................................. .....................................................................................................12 ........12

5. 5.1 5.2 5.3 5.4 5.5

BDEP (DEFINE PHASE) ..........................................................................................13 3D-CAD – BLOCK BLOCK MODEL GENERAL GENERAL ....................................................................13 CONSTRUCTION ............................................................................................ .....................................................................................................13 .........13 3D-CAD BLOCK MODEL SCOPE...........................................................................13 SCOPE ...........................................................................13 3D-CAD - BLOCK MODEL MODEL REVIEW ........................................................................15 3D-CAD BLOCK MODEL CHECKLIST ...................................................................17

6. 6.1 6.2. 6.3 6.4 6.5 6.6 6.7

EXECUTE PHASE (DETAIL ENGINEERING).........................................................19 3D-CAD MODEL GENERAL.....................................................................................19 3D-CAD 30 % MODEL SCOPE (EXECUTE PHASE) ..............................................20 3D-CAD 30 % MODEL REVIEW REVIEW (EXECUTE PHASE) PHASE) ............................................22 3D-CAD 60 % MODEL SCOPE (EXECUTE PHASE). PHASE). .............................................24 3D-CAD 60 % MODEL REVIEW REVIEW (EXECUTE PHASE) PHASE) ............................................25 3D-CAD 90 % MODEL SCOPE (EXECUTE PHASE) ..............................................26 3D-CAD 90 % MODEL REVIEW REVIEW (EXECUTE PHASE) PHASE) ............................................27

7.

ARCHIVING ........................................................................................... ..............................................................................................................28 ...................28

8.

REFERENCES ..................................................................................... .........................................................................................................29 ....................29

APPENDICES APPENDIX I

TYPICAL COLOUR CODE FOR 3D-CAD 3D-CAD MODELS .....................................30

APPENDIX II

CHECKLIST FOR THE MODEL REVIEW......................................................31

DEP 30.10.05.11-Gen. February 2012 Page 4 1.

INTRODUCTION

1.1

SCOPE This DEP specifies requirements and gives recommendations related to the BDEP (Define) and Execute (detailed engineering) phase of projects for: •

3D-CAD models.

•

3D-CAD visualisation and use of 3D-CAD features.

•

Model review sessions.

Level of detail for the Define Phase is described in (4), 3D-CAD Model. The quality of the model content shall be communicated to the Principal (i.e. content model based on preliminary information, piping based on “dummy/standard” specifications, etc.). Visualisation tools other than 3D-CAD tools (e.g. virtual reality) are not covered by this DEP. The use of such tools is subject to the agreement of the Principal. This is a revision of the DEP of the same number dated January 2005; a summary of the main changes is given in (1.5). 1.2

DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorised access to DEPs does not for that reason constitute an authorization to any documents, data or information to which the DEPs may refer. This DEP is intended for use in facilities related to oil and gas production, gas handling, oil refining, chemical processing, gasification, distribution and supply/marketing. This DEP may also be applied in other similar facilities. When DEPs are applied, a Management of Change (MOC) process shall be implemented; this is of particular importance when existing facilities are to be modified. If national and/or local regulations exist in which some of the requirements could be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to the safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible.

1.3

DEFINITIONS

1.3.1 1.3.1

General General defini tio ns The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal. The word shall indicates shall indicates a requirement. The word should indicates should indicates a recommendation.

DEP 30.10.05.11-Gen. February 2012 Page 5 1.3.2

1.4

Abbreviations Term

Definition

3D-CAD

Three Dimensional Computer Aided Design

BDEP

Basic Design Engineering Phase

CAD

Computer Aided Design

HFE

Human Factors Engineer

HSE

Health Safety Environment

HVAC

Heating Ventilating Air Conditioning

PFS

Process Flow Scheme

PEFS

Process Engineering Flow Scheme

TA

Technical Authority

VCA

Valve Criticality Analysis

CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets ( ). Other documents referenced by this DEP are listed in (8).

1.5

SUMMARY OF MAIN CHANGES This DEP is a revision of the DEP of the same number dated January 2005. The following are the main, non-editorial changes. Change Scope of block model changed to scope of 3D block model. Scope of model review re-defined. Notice period extended. Team composition updated. Checking method updated. Model colour codes changed. Write-up and references to physical block models are deleted. Method of informing the Principal before the formal review by the Contractor on completeness and quality of the model has been updated. Archiving procedure updated. Descriptions of completeness of model at 30 %, 60 % and 90 % stages are increased. Checklist for the model review has been extended.

1.6

COMMENTS ON THIS DEP Comments on this DEP may be sent to the Administrator at [email protected], using the DEP Feedback Form. The DEP Feedback Form can be found on the main page of “DEPs on the Web”, available through the Global Technical Standards web portal http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.

DEP 30.10.05.11-Gen. February 2012 Page 6 1.7

DUAL UNITS This DEP contains both the International System (SI) units, as well as the corresponding US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.


GENERAL In the course of the Define stage of a project, the construction of a 3D-CAD block model may be useful depending on the type, size and complexity of the plant. In the early phase of a project, the 3D modelling tool may be used for locating the buildings, main equipment and the main pipe routings. As part of BDEP (Define) Phase, a 3D-CAD block model should be constructed. As part of the Execute Phase (detail engineering) a 3D-CAD model shall be constructed. A 3D-CAD system is a design tool for the Contractor and an integral part of the design and engineering process. The visualisation used for the 3D-CAD "model review" is only one of the features of a 3D-CAD system. The 3D-CAD model reviews are performed by the Contractor at 3 stages during the design. The 3D-CAD system also provides a clash free design for all engineering disciplines involved, all the construction drawings and can assist in controlling the construction materials (through listings per unit, rack or class). The model provides a visual check on safety, operability, accessibility, maintainability and facilitates the engineering and erection of the units (erection path can be implemented in the model). It may also be used for the training of operators (including safety training) and for the planning of efficient maintenance schedules, to assist construction work (e.g. handling of heavy or large equipment) and commissioning planning.

DEP 30.10.05.11-Gen. February 2012 Page 8 3

MODEL REVIEWS

3.1

GENERAL The Contractor shall perform formal 30 %, 60 % and 90 % model reviews to check that the arrangements meet the Principal's requirements. The purpose of a 30 % model review in the Execute Phase, is to freeze the basic plot layout and to reach agreement on the proposed design to enable the Contractor to proceed into detail design. Where plot layout is critical, and as such affects feasibility, it is required to be executed as part of the BDEP (Define) Phase of the project. The purpose of the 60 % model review in the Execute Phase, is to confirm the design is in-line with the PEFS, Supplier data and all other design relevant documentation. After the review the Contractor should be able to finalise the deliverables for construction. The purpose of the 90 % model review in the Execute Phase, is to confirm on the comments from the 60 % and to finalise on the total design of the model. These reviews should be undertaken in detail, checking each unit for safety routes, operability, maintainability, accessibility and constructability and checking each system in the unit using the PEFS to make item-by-item checks. The modifications initiated during previous model reviews shall be implemented before the next official model review. The Contractor shall perform in-house model checks prior to the formal model reviews. The results of these in-house reviews shall be documented. Any changes which impact the results from prior reviews shall be brought forward to the Principal at start of the formal review. All items as listed for the relevant 30 %, 60 % and 90 % model reviews shall be part of the 3D model. Any deviation from the lists shall be reported by the Contractor to the Principal, well in advance of the formal 3D model review. Any necessary changes shall be agreed upon and immediately recorded and shall be marked with reference numbers and model pictures to allow proper follow up and to avoid misunderstanding. From each formal 3D-CAD model review, an electronic copy of the presented model shall be saved by the Contractor and handed over to the Principal (if required). When the Contractor, during the BDEP (Define) Phase, constructs a 3D-CAD block model, model reviews have to be held to check that the arrangements meet the Principal’s requirements. See (5): BDEP Define phase.

3.2

TOOLS A 3D-CAD model presentation for a group of people should be performed using a large screen having a high resolution. Point-to-point distance measurements shall be possible on request, to be able to verify compliance to clearance and access requirements or approve slight deviations. Main computer manipulations, such as switching to another process unit should not take more than 2 minutes. Reference items, mobile cranes, bundle pulling equipment, etc. and an operator of the same scale as the model under review, shall be available. The model operator's dimensions shall be conform to the the workspace design requirements of DEP 30.00.60.20-Gen. Deviations or "cultural calibration" can be done on regional level and approved by the appropriate HFE TA. It should be possible to save snapshots and to indicate on the overall picture (e.g. projected in the corner of the screen) where the review detail is located. The full model presentation should be given in a darkened room with sufficient dimmed light to enable drawings to be read and notes to be made without interfering with the presentation. The review must be held in a room that is fit for purpose (enough space and good view on the 3D model). A sufficient number of pointers should be available to point to items shown on the screen and to improve the efficiency of discussions.

DEP 30.10.05.11-Gen. February 2012 Page 9 The following information shall be available in clear legible prints for all participants: a) Process Flow Schemes (30 %); b) Process Engineering Flow Schemes (60 %, 30 % as far as available); c) Plot Plan; d) Equipment arrangements; e) Line List + Critical Line List (through computer access to project documentation system during review); f) Individual equipment information, data sheets (on request); g) Civil structural drawings (on request); h) Stress calculations (on request); i) Piping studies (through computer access to a dedicated electronic folder during review); j) Material (equipment) handling studies; k) Fire safety studies; l) HSE reviews; m) Listing of agreed standards; n) Level of completeness of model (Clash report) and quality of catalogues. 3.3

TEAM COMPOSITION A team leader from the Contractor shall be appointed who is fully familiar with the project, the model and the 3D-CAD system capabilities. The team leader shall guide the team through the model with the assistance of the system operator. The team leader shall be responsible for the efficiency of the review process, the adequate reporting of comments made and the subsequent follow-up. The efficiency of the model review largely depends on the experience and knowledge of the system operator and secretary. Both the system operator and secretary shall be fluent in the project language, and should understand the technical terms used within the industry. The system operator should be heavily involved in the design of (the area of) the model under review. He is familiar with the technical content of the model and can clarify the design to the team members when necessary. A secretary shall be available to take meeting notes, and throughout the full review, take down any comments without discussion, To prevent specialist sub-meetings during a model review, which distract the attention of other team members, teams should not be larger than 10 members excluding the contractor specialists. If a larger number of people is necessary for a model review separate teams should be formed of members with a common interest in the subject(s) under review. Each team shall than review the model independently, and at the end of the review the team leader shall plenary discuss any conflicting recommendations made by each individual team. The composition of the review team depends on the progress of the model.

3.4.

HANDLING OF COMMENTS The 3D Model Review Minutes shall encompass all the comments made in the session, state the actions to be taken, the responsibilities and time frame of implementation After every review (30 %, 60 %, 90 %), the Principal team shall decide if the level of completion of the model is in line with the requirements defined in (6.2) and (6.3). Shortcomings in the degree of completion shall be highlighted and, after correction, checked in the next review, or in an additional review depending on the degree of incompleteness and the project schedule.

DEP 30.10.05.11-Gen. February 2012 Page 10 Comments on the model shall be electronically tagged during the review . The 3D-CAD tools

should have sequence reference facilities to describe the comments given by the review team. The text of each reference shall be complete and unambiguous and include a “snapshot” to avoid confusion in a later stage of the review process. Electronic tag files shall be archived as a permanent record of review comments. A Log List shall be applied for the Review Sessions in order to keep record for all comments.

The team leader shall co-ordinate the tag handling process. The tagged items shall be reviewed by the Contractor within 2 weeks and a record shall be produced showing which tag items will be implemented or rejected, with reasoning. The relevant specialist or technical authority as appropriate shall be consulted, and the other team members shall be informed, before a tag item is deleted or significantly changed. The Contractor may proceed when deviations or non compliances are agreed and approved by the appropriate TA present in the 3D model review. However audit trail for deviation/ derogation register shall be followed up by the Shell project team. Before the next review starts, all agreed tag items shall be implemented in the 3D-CAD model.


3D-CAD MODEL

4.1

GENERAL The 3D-CAD model is a collection of graphical data which describes the facilities of a plant or offshore installation for design and visualisation purposes. The 3D-CAD model can be accessed via a 3D-CAD system. The graphical data is an integral part of an engineering database supporting the design process. The 3D-CAD engineering database enables the integration and consistency of the different design stages and the different subjects, such as piping, foundations, tabletops, steel structures, equipment, instrumentation, electrical equipment, buildings and Heating, Ventilation and Air Conditioning (HVAC) equipment into one 3D-model. Typical deliverables of a 3D-CAD system include: a) Detailed engineering drawings such as plan and elevation drawings for piping, structural, civil, instrumentation and electrical; b) Plot plans; c)

Plot elevation drawings;

d) Piping isometrics; e) Vessel trim isometrics; f)

Commissioning system drawings;

g) Material Take-off (Bills of Material); h) Reports such as line lists, instrument data, interference checks (clash reports) and valve data. Each discipline should create their design within the 3D model, only then an interference free design can be ensured. The Contractor has to inform the Principal before the formal 30 % 3D model review, which individual disciplines (e.g. piping, structural, civil, electrical, etc.) are creating their designs in the 3D-CAD model and which deliverables each discipline extracts from the 3D-CAD model. 4.2

SAFETY, OPERATIONAL AND MAINTENANCE ASPECTS The 3D-CAD system shall be structured in such a way that all disciplines involved can check whether sound design and engineering criteria have been met with respect to safety, operability and maintenance and facilitate the engineering and erection of the plant. This shall include accessibility for maintenance, operations and fire fighting, location of valves, constructability, process instrumentation, routing of the piping adequate for the process, location of emergency shut-down stations, proper and safe location of vents and drains, engine exhausts, accommodation air intakes, location of fire protection and firefighting equipment, access egress and escape routes.

4.3

AT THE CONSTRUCTION SITE A 3D-CAD review system should be made available at site, to provide information during construction for aspects such as transport and erection of equipment, the routing of piping, positioning of structural steel, platforms, cable trenches, trunking and channels. During the construction of the process unit the pre-defined free areas (e.g. maintenance space, escape routes) in the 3D-CAD model shall remain free from items that are not presented in the 3D-model, though are constructed in the field (e.g. small bore piping, tubing, secondary cable trenches, tracing.) Contractor has to check the availability of “free space” in the 3D model, prior to field route piping, instruments or electrical trenches.

DEP 30.10.05.11-Gen. February 2012 Page 12 4.4

INSTRUCTION The 3D-CAD model may be used for training and instruction of plant operators, construction staff, maintenance staff and emergency response organisation.

4.5

FEATURES WITH 3D-CAD TECHNOLOGY The required features shall be agreed between the Principal and the Contractor before the set-up of the 3D-CAD system and engineering database is started. The 3D-CAD system should be programmed to provide reports regarding situations where certain criteria are not met. This approach can substantially improve the efficiency of the model review. Only the differences to the criteria need to be checked during the model review. The application of 3D-CAD technology allows: a) Definition of classified 3D-shapes (soft boxes) to indicate free volumes in order to: •

Check for the absence of unwanted equipment in certain area classification zones;

•

Check headroom available;

•

Check accessibility for inline instruments;

•

Check absence of tripping hazards;

•

Check absence of obstructions in access and escape routes;

•

Check correct location of valve handwheels;

•

Check for reach and clearance for activities;

•

Check vertical access for lifting and cranes.

b) Identification of deviations from normal engineering practices; c) Modelling of foundations and underground systems; d) Combining a 3D-CAD model with a 3D scanned model from the existing situation at the site; e) Review of proposed material handling strategies and equipment design. 4.6

REQUIREMENTS Where practical, the colours used in the 3D-CAD model shall be in accordance with (Appendix I). The 3D-CAD design lead engineer is to advise if specific colour coding is achievable. The Principal shall approve alternative colour convention. Colour coding shall also be used to indicate the status of equipment, valves and piping during the various model reviews (i.e. built according to final information or indicative only). Category I Criticality DEP 30.00.60.13-Gen.

ratings

of

valves

to

be

colour

coded

as

indicated

in

The 3D-CAD model shall be set up such that images of items can be presented separately (e.g. when only steel structures are shown and all other items are suppressed). For complex areas, separate review files of floors or smaller units should be set up to make detail review possible.


BDEP (DEFINE PHASE)

5.1

3D-CAD – BLOCK MODEL GENERAL A block model means that the representation of the equipment as shown is for visualisation purpose only because of the absence of more detailed information on the items. The project specific specifications for modelling the individual components are usually not yet created in the 3D system at this phase in a project. The 3D-CAD block model may be used for evaluating different lay-out options and to establish the location of main equipment and the main pipe routings, taking into account the required safety distances and accessibility for construction, operation and maintenance. After approval of the layout by the Principal, it can be used as a basis for preparing a more detailed (initial) plot plan drawing. When a 3D-CAD block model has been made it should be used as the basis on which further 3D-CAD modelling will be developed.

5.2

CONSTRUCTION In a 3D-CAD block model, the equipment, buildings etc. shall be modelled in a simplified way. All different types of components modelled, shall have their own colour coding (see Appendix I). Plant layout studies and piping studies form the basis of the model. These studies will also establish pipe track widths, structures, etc. The routing of main electrical and instrument cable trenches and access ways / roads should be shown.

5.3

3D-CAD BLOCK MODEL SCOPE

5.3.1

Introduction A block model should be set up during the Define Phase for one process unit or for multiple process units inclusive or exclusive of the neighbouring facilities, buildings and structures. Separation distances of the process and DEP 80.00.10.11-Gen. and DEP 80.00.10.12-Gen.

utility

facilities

A 3D-CAD block model should include the items as given below. 5.3.2

3D-CAD bloc k model Scope of the overall sit e 3D-CAD block model Scope of the overall site Process/utility units Buildings (e.g. control room, administration or workshop, etc.) Interceptors Effluent treatment facilities Flare-stack area. Jetties and marine facilities Pump stations Roads Storage tanks and tank farms LNG/LPG storage facilities Blending plants.

shall

conform

to


Battery limit locations Pipe racks / pipe tracks / pipe trenches Future extension plot-determining equipment Indication of space required for plot-determining piping Structures The routing of main electrical and instrument cable trenches Elevation differences of the site “terraces Helidecks, helipads and helicopter facilities Hose handling areas Laydown areas Fixed cranes Major maintenance areas Indication of paving type (heavy duty, etc.) Indication of location of existing underground facilities (firewater, coolwater, etc.) Communication towers Life boat stations Indication of fences Rail and road loading facilities. Bund walls to be shown around Tank Farms.

5.3.3

3D-CAD bloc k model Scope of a proc ess unit 3D-CAD block model Scope of a process unit Furnaces Stack locations Equipment including identification (e.g. columns, heat transfer equipment, vessels, reactors, pumps Access/ egress to be indicated Transfer pipe(s) from furnaces to columns or reactors Reactors and solids handling facilities / storage areas (e.g. for catalyst) Plot area for pulling furnace tubes, convection bank tubes and heat exchanger bundles Vessels Heat exchanger areas, including horizontal or vertical reboilers and large individual heat exchangers and reboilers Compressors and compressor buildings (inclusive lay-down areas) Gas turbine buildings Pipe bridges and structures for air-cooled heat exchangers Battery limit of incoming and outgoing pipes per unit or complex of units


Main electrical and instrument cable routings and trenches Buildings (sub stations, field auxiliary rooms, analyser houses) Main pipe racks / pipe tracks Indication of space required for plot determining piping and/or ducting Structures Indication of location of existing underground facilities Major maintenance hoisting areas 5.4

3D-CAD - BLOCK MODEL REVIEW

5.4.1

General Team review members shall be given adequate notice (approximately 3 months and confirmation 6 weeks) before the block model review date, and they shall be informed of the location, duration, participants, type of review and the type and number of drawings, which are the basic documents for the constructed block model under review. Before a block model review starts, relevant documentation shall be made available to the members of the review team for prior familiarisation, i.e., plot lay-out drawings and Process Flow Sheets.

5.4.2

Tools Plot lay-out drawings and all PFS and PEFS which have been used for the build-up of the 3D block model shall be present.

5.4.3

Team compo sit ion A team leader from the Contractor shall be appointed who is fully familiar with the project and the 3D block model. He shall guide the team through the model. The team leader shall be responsible for the pre-reading material, the efficiency of the review process, for the adequate recording of comments and for the subsequent follow-up. Since the 3D block model shows the main separation distances between plants, storage areas, buildings and main equipment inside plants which are the basis for a safe, operable and maintainable complex, the model should be reviewed during the earliest stage of the Define engineering activities by a team representing at least the following disciplines: Process technology; Operations; Maintenance; Plant lay-out; Technical safety; Civil/ Structural; Human factors engineering; Mechanical; Electrical; Construction; Projects.


Handling of comm ents After the 3D block model review, the agreed comments shall be distributed to the representatives and be implemented in the model. It should be agreed whether a second review is required.

5.4.5

Define engineering phase model reviews When model reviews are performed during the Define Engineering Phase, the value to the project and the quality of the model needs to be defined by the Contractor and agreed with the Principal. The reviews held can also follow the 30 % to 90 % review timing and checklist as guidance, but quality and the reviewed content shall be concluded before the meetings. Reviews held in the Define Phase can in some cases receive the Execute Phase completeness level, when the documents to which the 3D model was built are in the “issue status level” as indicated below. During an official 3D model review, the completeness level of the model has to conform to the requirements as given in (6.2), (6.3), (6.4) or (6.5). Completeness of documents shall be as per table below: Define phase (BDEP)

Execute phase 30 % (Detail eng).

EPC phase 60 % (Detail eng).

Line list

Preliminary info

Issued for design

Issued for final

Critical line list

No detailed info. available

List complete and issued for design.

Critical lines

Large bore lines routed, Critical lines not defined.

All lines on the critical All lines routed linelist to be routed with their stress calculations done. All Piping defining Equipment positions to be routed.

PEFS

Preliminary info.

Issued for detailed design.

Issued for final info.

Equipment information

Basic information available

Dimensions according to vendor information and nozzle info. available.

Issued for final

Pipe specifications in 3D model

Piping specifications not loaded in the 3D model (standard specifications)

Pipe specifications loaded in the 3D model

Pipe specifications loaded in the 3D model

Modelled pipe lines

Piping modelled to “standard specifications”

Piping modelled to the project pipe specifications as loaded in the 3D model.

Piping modelled to the project pipe specifications as loaded in the 3D model.

All 30 % review comments included.

On the Define/ BDEP documents of the pre-Execute Phase, the completeness level shall be indicated.


3D Model catalogue specif icati ons At the start of a project in the Define Phase, there are usually no project specific specifications loaded in the 3D model catalogue. To be able to create components in the model, the Contractor can start the first modelling work by using standard specifications. The Contractor shall fill the 3D model catalogue with project specifications at the start of the projects execute phase and at the 30 % model review all individual discipline project specifications shall be in the 3D model (piping, instrumentation, electrical, civil, etc.) All components at the 30 % model review shall be modelled according to the project specifications. Project specific components, which are falling outside the normal discipline specifications, have to be developed during the execution phase. Until the time that the project specific component are developed, a replacement component should be used indicating the outline of the item. Until the final dimensions of the project specific component are known, conservative outline dimensions should be taken into account.

5.5

3D-CAD BLOCK MODEL CHECKLIST

5.5.1

General In this paragraph checkpoints are given for the review of a 3D-CAD block model. The checklist will help to improve quality and to identify and eliminate potentially hazardous situations. The scope of this checklist is applicable to oil refineries, chemical plants, gas plants, exploration and production facilities (onshore and offshore), supply/marketing installations and to specific items such as storage facilities and/or jetties, road/rail loading facilities and complicated manifolds. The checklist is comprehensive but should not be considered to be fully exhaustive. Include the following considerations for each item mentioned in the scope of a 3D-CAD block model.

5.5.2

Overall sit e plan General Layout considerations

5.5.2.1

Is the proposed set-up logical and optimal with respect to process integration?

5.5.2.2

Are roads properly defined with respect to their logical approach to unit(s)? Consider also the Movements area, including its marine location and rail and road connections. Include road dimensions, considering main roads (unrestricted) and restricted access roads.

5.5.2.3

Is erection possible during construction: furnaces, columns, large vessels, reactors, air-cooled heat exchanger structures, flare header and flare plot?

5.5.2.4

Have area classification requirements been taken into account?

5.5.2.5

Is the location of the Utilities area logical and optimal in relation to the process units?

5.5.2.6

Is the location of the Movements area logical and optimal in relation to the process units?

5.5.2.7

Is the prevailing wind direction considered in relation to the location of tank farms, LPG storage or gas plants, buildings, stacks, flare and oil collecting systems, like sewers, oil catcher basins, air cooler banks and areas containing H2S or HF?

5.5.2.8

Has a sterile area been provided around the flare stack?

Y

N

NA


5.5.2.9

Have appropriate separation distances been taken into account between units, storage areas and buildings as well as public fences?

5.5.2.10

Have interfaces for future extensions been considered?

5.5.2.11

Have main maintenance and storage areas been taken into account?

5.5.2.12

Have existing underground obstructions been identified and implemented in the model

5.5.2.13

Has demolition scope been indicated in the layout

5.5.2.14

Have main crane locations and lifting paths been indicated in the model

5.5.2.15 Are the battery limit locations been identified and/ or any major interface connection (i.e. large coolwater lines, firewater lines, etc.) 5.5.3

Process Units General Layout considerations

5.5.3.1

Have separation distances within the plot area been taken into account? Consider furnace, column, main equipment, flare, any vent outlet to 'safe location', oil collecting area like sewers

5.5.3.2

Is the routing of the main piping in bridges and via trenches defined?

5.5.3.3

Is the location of the battery limit specified (by unit or complex)?

5.5.3.4

Is a maintenance area available e.g. for pulling of heat exchangers bundles?

5.5.3.5

Is a maintenance area available for furnace tube pulling?

5.5.3.6

Is a maintenance area available for removal of large pieces of rotating equipment such as compressors or gas turbines? Is a protective compressor building required?

5.5.3.7

Are there sufficient maintenance access ways available towards large air coolers

5.5.3.8

Is the area sufficient for e.g. catalyst or solid handling activities?

5.5.3.9

Is the paving designed to support heavy equipment and cranes?

5.5.3.10

Is sufficient lay down area available?

Y

N

NA


EXECUTE PHASE (DETAIL ENGINEERING)

6.1

3D-CAD MODEL GENERAL Prior to the official model reviews, the Contractor has to confirm in writing to the Principal that the content of the model is according to the 30 %, 60 % and 90 % listing. See (6.2) to (6.7). The model shall also be in-line with the latest revision of the PEFS and equipment information. Deviations shall be reported to the Principal well in advance of the official model review. The 3D-model shall be checked against the latest issue of the PEFS, equipment information and plot layouts (when not extracted from the model). Team review members shall be given adequate notice (approximately 3 months and confirmation 6 weeks) before the review date, and they shall be informed of the location, duration, participants, type of review and the type and number of drawings, which are the basic documents for the constructed model under review. Before a model review starts, relevant documentation shall be made available to the members of the review team for prior familiarisation: 30 % model review:

plot lay-out drawings and Process Flow Sheets;

60 % model review:

Minutes of Meeting of the 30 % model review with status of follow up comments, plot layout drawings.

The actual process design as given on the PEFS should not be checked during the model review. If the model review, however, leads to a more economical solution without jeopardising the design functionality or safety, this change may be implemented and the PEFS shall be made consistent with the 3D-CAD model. Such proposals shall be brought to the attention of the project manager. Mark on the 3D-CAD system or on the PEFS all the pipes, equipment and instrumentation that have been checked and accepted. Indicate the points that have not been accepted, to facilitate the review in follow-up checks. Ensure that when a modification is proposed it suits its purpose, and does not conflict with other requirements. Ensure that it is practical, safe, in accordance with the PEFS and also economic. If in doubt, consult the appropriate specialists of other disciplines. The checklist of (Appendix II) should be used during the model review. Note that the checklist is not exhaustive and shall not overrule the detail design requirements contained in the project specifications where appropriate. Detailed design requirements associated with the checklist items can be found in the following documents: Definition of temperature, pressure and toxicity levels

DEP 01.00.01.30-Gen.

Human factors engineering in projects

DEP 30.00.60.10-Gen.

Human factors engineering – Valves

DEP 30.00.60.13-Gen.

Human factors engineering - Workspace design

DEP 30.00.60.20-Gen.

Human factors engineering – Design and procurement, skid-packaged units

DEP 30.00.60.18-Gen.

Loading facilities for bulk road vehicles

DEP 31.06.11.11-Gen.

Hoisting facilities and weather protection for rotating equipment

DEP 31.25.00.10-Gen.


Piping - General requirements

DEP 31.38.01.11-Gen.

Instruments for measurements and control

DEP 32.31.00.32-Gen.

Electrical engineering design

DEP 33.64.10.10-Gen.

Roads, paving, surfacing, cable trenches, slope protection and fencing

DEP 34.13.20.31-Gen.

Drainage and primary treatment facilities

DEP 34.14.20.31-Gen.

Design of blast resistant onshore buildings, control rooms and field auxiliary rooms

DEP 34.17.10.30-Gen.

Onshore steel structures

DEP 34.28.00.31-Gen.

Design of jetty facilities (amendments/supplements to BS 6349-1/2/4)

DEP 35.00.10.10-Gen.

Area classification

DEP 80.00.10.10-Gen.

Layout of onshore facilities

DEP 80.00.10.11-Gen.

Layout of offshore facilities

DEP 80.00.10.12-Gen.

Design of pressure relief, flare and vent systems

DEP 80.45.10.10-Gen.

Assessment of the fire safety of onshore installations

DEP 80.47.10.30-Gen.

Stairways, general arrangements

S28.001

Ladder, general arrangements to columns, stack and structures

S28.011

The progress of the model is expressed in the percentage completed compared to the final engineering. Reviews of the model shall take place when the engineering as reflected in the model is 30 %, 60 % and 90 % complete. The line-up shall be followed systematically and strict attention shall be paid to details, since seemingly minor items can cause accidents. Start, for instance, with an overall view of the complete plant, then zoom in on the applicable plot and review unit by unit. For each unit give an explanation of the functionality, point out the main equipment and the critical pipe lines. Review the location philosophy, the maintenance access, safety routes and the operatability of all equipment. Review the critical line routings and location of the valves. Sub-contracted work and package Supplier equipment shall be shown in the model with the same level of detail as described above. The main engineering Contractor shall translate any engineering deliverables available from the above mentioned sub-contractors into the plant 3D Model. Only in the case that the spec for package units identifies such for a specific package unit, an alternative method shall be used. For this reason, a specification for human factors engineering and review requirements should be set-up and discussed with the Supplier during the bid clarification meeting. 6.2.

3D-CAD 30 % MODEL SCOPE (EXECUTE PHASE) The items lis ted below should be included in t he 30 % model review, plus any other items whic h are applicable for t he particul ar project.

6.2.1

Location and orientation of all equipment (incl. supporting method, lifting lugs, insulation) and all space consumers (incl. pulling volumes and future extensions)

6.2.2

Nozzle and manway orientations/ locations (including swing space of covers).

Y

N

NA


6.2.3

Structures (steel and concrete inclusive fire proofing)

6.2.4

Platforms incl. stairs and ladders. Essential for operation maintenance and escape.

6.2.5

Critical lines, from critical line list (Lines determining the location of equipment and large size pipe determing the plot layout).

6.2.6

Plot determining piping / ducts (including all 6 in. and larger, routing only, underground as well as above ground)

6.2.7

Utility station locations

6.2.8

Eye wash and safety shower locations

6.2.9

In-line instruments (preliminary information)

6.2.10

Blast walls

6.2.11

Bund walls

6.2.12

Maintenance access ways (All including their clash volumes) essential for main access/ operation/ influence on safety. This includes a representation of main maintenance equipment and trolleys and trucks as applicable

6.2.13

Major piping that influences equipment positions (underground as well as above ground).

6.2.14

Concrete slabs, paving and roads (different load bearing capacities shall be recognised).

6.2.15

Relevant floor slopes, where the fall is >50 mm (2 in) over the floor width

6.2.16

Package unit location and orientation (basic shapes and main components recognisable inside these package units, the escape ways shall be defined).

6.2.17

Escape routes on grade and elevation (including their volumes)

6.2.18

Pipe racks and main pipe support structures, sleeper ways, culverts, etc.

6.2.19

Outline of underground electrical and instrumentation trenches

6.2.20

Main electrical and instrumentation cable trays / racks [200 mm (8 in)] and wider).

6.2.21

Main panels – outline

6.2.22

Main steel and bracing allocations

6.2.23

Underground sewer systems and collecting and separation systems drainage / sewage

6.2.24

Buildings in outline, e.g. control room, analyser houses, switch rooms

6.2.25

Drop zones/ bundle pulling areas/ laydown areas

6.2.26

Mobile crane aprons (based on available cranes and on lifting study)

6.2.27

Relevant Cranes, Hoisting equipment, lifting beams, monorails (+travel path), maintenance cranes

6.2.28

Major pipe-chases in structure and buildings (reserved areas for future piping)

6.2.29

Major wall and floor openings for equipment travel

6.2.30

Unit and/ or equipment safety distances, area classification requirements

6.2.31

Constructability volumes (incl. location of lifting slings at any time during lifting).

6.2.32

HVAC equipment incl. large size ducting


6.2.33

Firewater hydrants, monitors (and hose reels)

6.2.34

Underground firewater lines incl. valves and hydrants

6.2.35

Equipment status (filled in attribute)

6.2.36

Define separation distances within the plot to be taken into account

6.2.37

Interfaces for future extensions and space for future equipment to be taken into account

6.2.38

Area classifications requirements been taken into account

6.2.39

Location of battery limit to be specified (by unit or complex)

6.2.40

Sufficient area for catalyst, solids or bag filter handling

6.3

3D-CAD 30 % MODEL REVIEW (EXECUTE PHASE) The objective of the 30 % model review is, to freeze a basic plot layout and getting agreement on the proposed design to enable the Contractor to proceed to detail design. The focus of a 30 % model review is on accessibility, sa fety, layout, human factors engineering, maintainability and construction. To be provided by the Contractor to the Principal in writing before the 3D-CAD formal model reviews : - Agenda incl: review sequence, highlights and main items of the unit, items on hold, remarks and disciplines to attend (minimum 2 weeks in advance), list of lines for review - Filled out 3D model standards settings form (Appendix II, 11.0) - Confirmation that: •

Model includes all items as listed under (6.2),

•

Piping inline with the latest revision of the PEFS

•

Equipment is modelled according to vendor data.

- Any deviations or areas, equipments, lines on hold shall be communicated in writing well in advance of the formal model review. - Confirmation of a clash free design, shall be supported with a clash report. - Confirmation that all lines from the critical linelist and all other lines which are determining the equipment locations or are critical for the plot layout, shall be modelled against the actual piping class (not to a dummy specification). - Visualise piping modelled against actual piping class or dummy class by colour coding. - Equipment status report: preliminary/ according vendor data/ final (indicated status by color code in the model) - PEFS, which shall remain legible when printed on both A3 size paper, as well as on 11 x 17 in (ANSI B) size paper, or when printed on both A1 size paper, as well as 22 x 34 in (ANSI D) size paper - Equipment arrangements, which shall remain legible when printed on both A3 size paper, as well as on 11 x 17 in (ANSI B) size paper - Plot plan, Equipment data sheets and piping study dwg’s (on request or electronically).


To be provided after the reviews - Saved electronic copy of the 3D review model. - Updated Equipment arrangements for design (on request). - List of the lines, which were reviewed and approved. - Minutes of meeting + (list of outstanding action Items)

At least the following disciplines shall be represented in the 30 % review team: Process technology

(Full time);

Operations

(Full time);

Maintenance

(Full time);

Plant lay-out and piping

(Full time);

Technical safety

(Full time);

Civil / Structural

(Full time);

Projects

(Full time);

Human Factors Engineering

(Full time);

Construction engineer

(Full time);

Mechanical

(on call);

Process Automation and Control

(on call);

Electrical

(on call);

Construction manager

(on call).

A rotating equipment representative may occasionally extend the team, especially if extraordinarily large pieces of rotating equipment need to be installed and maintained. Other relevant specialists should be consulted at an early stage of model design if required (e.g. for solids handling, slurry transport, etc). The Human Factors Engineering design analysis results such as the Valve Criticality Analysis (VCA) shall be used as input to the 30 % model review. The 30 % model review shall be concluded with a statement describing which aspects are frozen at this stage.


6.4

3D-CAD 60 % MODEL SCOPE (EXECUTE PHASE). The 60 % model review shall be concluded with a statement describing which aspects are frozen at this stage. The items li sted below shoul d be incl uded in the 60 % model review, plus any other items whic h are applicable for the particular proj ect.

6.4.1

The actions resulting from the 30 % model review

6.4.2

Location of spading points (incl. handling)

6.4.3

Process and utility lines (2 in. and above) incl. supports, flow measurements and main instrumentation

6.4.4

All other piping largely completed

6.4.5

Equipment to latest information, including orientation of nozzles

6.4.6

Ladders, stairs and platforms

6.4.7

Valving (position, orientation, etc.)

6.4.8

Control valves with access

6.4.9

Platforms for valves, equipment and operation

6.4.10

Permanent cranes, hoisting beams pad eyes, etc. (based on material handling study)

6.4.11

Hoisting equipment, lifting beams, monorails and davits (hoisting and transport devices for routine maintenance of equipment or components in excess of the manual handling requirements contained in DEP 30.00.60.20-Gen.)

6.4.12

Final dimensions of table tops, structures and steel constructions

6.4.13

Secondary steelworks and bracing

6.4.14

Secondary foundations – outlines

6.4.15

Eye wash and safety shower locations

6.4.16

Pipe supports locations and types (physically supported), for piping 3 in. and above and all critical piping. (supports for stress critical systems shall be based on stress analysis calculations).

6.4.17

Secondary supports such as trunnions, supporting steel, brackets, etc. (for clash check purposes)

6.4.18

Local operation panels, all instrumentation on equipment

6.4.19

Fire fighting systems (hydrants, monitors, water spray systems, etc;)

6.4.20

In-line Instruments based on final vendor data

6.4.21

Instrument transmitters and outlines of junction boxes, secure instrument air vessels; panels and cabinets inclusive stands, safety critical sensors / switches

6.4.22

Withdrawal volumes for instruments

6.4.23

PSV Locations

6.4.24

Electrical equipment such as outdoor panels, major lighting towers

6.4.25

Above/ underground electrical + instrument cable trays – outline drops to all users

6.4.26

Above-ground instrumentation and electrical tray routing

6.4.27

Buildings, substation, (incl. crane and HVAC)

Y

N

NA


6.4.28

Package units shall be modelled (equipment, piping, associated instruments, etc.) based on package vendor general arrangement drawings (additional statement in [6.1])

6.4.29

All HAZOP comments incorporated

6.4.30

Utility stations

6.4.31

Outlines of steam tracing manifolds

6.4.32

Operating vessels for Remote Operated Valves (ROVs), (hydraulic and pneumatic)

6.4.33

Fireproofing

6.4.34

Pits and trenches

6.4.35

Battery limit valves layout

6.4.36

All access ways and maintenance access

6.4.37

Silencers

6.4.38

Fire and gas detectors

6.4.39

Local emergency stop buttons (outline)

6.5

3D-CAD 60 % MODEL REVIEW (EXECUTE PHASE) The focus of a 60 % model review is on engineering and technology. The 60 % model review shall be carried out and closed out prior to issuing the piping isometrics for construction. At least the following disciplines shall be represented in the 60 % review team: Process technology;

(Full time);

Operations;

(Full time);

Maintenance;

(Full time);

Plant lay-out and piping;

(Full time);

Technical safety;

(Full time);

Civil / structural;

(Full time);

Projects;

(Full time);

Instrumentation;

(Full time);

Electrical.

(Full time);

Construction engineer

(Full time);

Human factors engineer

(Full time);

Construction manager.

(On call).

Other relevant specialists should be consulted if required (e.g. fire safety and rotating equipment). Discussion of implementation of agreed comments from the 30 % reviews shall be part of the 60 % model review. The 60 % model review checks whether the physical layout is in line with the PEFS. The human factors engineering design analysis results shall be used as input to the 60 % model review.

DEP 30.10.05.11-Gen. February 2012 Page 26 The Contractor shall perform a full line-by-line check against the latest revision of the Process Engineering Flow Schemes, prior to the formal 60 % model review. Contractor to confirm well in advance of the 60 % model review, that PEFS check has been performed and which deviations have been identified. The Principal will perform a random check to verify the quality of the model. Contractor shall info rm the Principal prior to the 60 % model review on :

- Units, areas or equipment which are on hold. - Lines ready for review, Contractor shall ensure that lines are inline with PEFS, supports are indicated on the lines (Physically modelled) and lines are clash free, confirmation of clash free design shall be supported with a clash report. - Status equipment; Preliminary/ according vendor data/ final. Indicate status with colour coding in the model and in equipment status list. - Status of incorporation of the 30 % model review comments. - Status of the valves modelled; indication has to be given if valves are modelled according final vendor information (with the handwheel and lever locations) or still indicated with preliminary information. Differences shall be indicated by colours. - Status instruments (based on final or preliminary info). - Status of plot and equipment arrangements drawings (they should be extracted from the 3D model and clearly show revisions and items on hold). - Status of the structural steel in the model. - The status of all underground routings (piping, civil, elec./ instrum. incl. existing obstructions). Underground routings should be final at 60 %, any parts on hold shall be indicated. - Status of maintenance, safety, accessibility and obstruction volumes (to be clash free). - During the formal 60 % model review: All critical lines shall be reviewed; All non-critical lines shall be reviewed on an as needed basis as decided by Principal.

6.6

3D-CAD 90 % MODEL SCOPE (EXECUTE PHASE) This revision is intended to be a confirmation of the results of the 60 % model review. The model shall be compl eted to include:

6.4.1.1

Any late or special items

6.4.1.2

Any change since the previous reviews

6.4.1.3

All remaining utility piping

6.4.1.4

HFE comments incorporated.

6.4.1.5

Model shall be in accordance with the latest issue of the PEFS, linelist, structural, civil, instruments and equipment vendor drawings

6.4.1.6

Auxiliary piping for equipment-compressor skids, pump coolers/ seal piping

Y

N

NA


6.4.1.7

Remaining process and utility piping 40 mm (1 ½ in) and below

6.4.1.8

All stress reviews completed

6.4.1.9

Valving all sizes, instruments and supporting shown

6.4.1.10

All cable trays incl. tray supports

6.4.1.11

Instrument junction boxes, local control panels and instrument support stands

6.4.1.12

All auxiliary equipment and electrical motors shown

6.4.1.13

All sprinkler systems shown

6.4.1.14

Final lighting

6.4.1.15

Transmitter boxes

6.4.1.16

Sample stations

6.4.1.17

In-line instruments final

6.7

3D-CAD 90 % MODEL REVIEW (EXECUTE PHASE) For a 90 % model review, the composition of the review team should be identical as for the 60 % review. The team shall review the model on the added details such as the location of junction boxes, instrumentation, sample point locations and steam manifolds (e.g. smothering and tracing). Model 90 % complete: •

•

•

The actions resulting from the 60 % model review are resolved; The model shall be substantially complete, including instrumentation. Final comments shall be made at this stage; After all the comments from the 90 % model review have been implemented into the 3D model, no additional changes or updates to the 3D model are allowed without the approval by the Principal.


ARCHIVING

3D Block model (Define Phase) If specified by the Principal, an electronic copy of the complete 3D model shall be made available by the contractor, including the complete listing of the model review comments. 3D-CAD Detail design model If specified by the Principal, an electronic copy of the complete 3D model shall be made available by the contractor, including the complete listing of the model review comments. If specified by the Principal, colour prints-outs (screen dumps) from various angles shall be taken of the 3D-CAD model upon completion. Close-up views shall also be taken if specified by the Principal. The above print-outs shall be handed over to the Principal for archiving. After each formal 30 %, 60 % and, 90 % model review an electronic copy shall be handed over to the Principal for archiving.


REFERENCES In this DEP, reference is made to the following publications: NOTES:

1. Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions thereto. 2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell Wide Web) at http://sww.shell.com/standards.

SHELL STANDARDS Definition of temperature, pressure and toxicity levels

DEP 01.00.01.30-Gen.

Human factors engineering in projects

DEP 30.00.60.10-Gen.

Human factors engineering – Valves

DEP 30.00.60.13-Gen.

Human factors engineering - Workspace design

DEP 30.00.60.20-Gen.

Human factors engineering – Design and procurement, skid-packaged units

DEP 30.00.60.18-Gen.

Loading facilities for bulk road vehicles

DEP 31.06.11.11-Gen.

Hoisting facilities and weather protection for rotating equipment

DEP 31.25.00.10-Gen.

Piping - General requirements

DEP 31.38.01.11-Gen.

Instruments for measurements and control

DEP 32.31.00.32-Gen.

Electrical engineering design

DEP 33.64.10.10-Gen.

Roads,paving, surfacing, cable trenches, slope protection and fencing

DEP 34.13.20.31-Gen.

Drainage and primary treatment facilities

DEP 34.14.20.31-Gen.

Design of blast resistant onshore buildings, control rooms and field auxiliary rooms

DEP 34.17.10.30-Gen.

Onshore steel structures

DEP 34.28.00.31-Gen.

Design of jetty facilities (amendments/supplements to BS 6349-1/2/4)

DEP 35.00.10.10-Gen.

Area classification

DEP 80.00.10.10-Gen.

Layout of onshore facilities

DEP 80.00.10.11-Gen.

Layout of offshore facilities

DEP 80.00.10.12-Gen.

Design of pressure relief, flare and vent systems

DEP 80.45.10.10-Gen.

Assessment of the fire safety of onshore installations

DEP 80.47.10.30-Gen.

Stairways, general arrangements

S28.001

Ladder, general arrangements to columns, stack and structures

S28.011

DEP 30.10.05.11-Gen. February 2012 Page 30 APPENDIX I 1.

TYPICAL COLOUR CODE FOR 3D-CAD MODELS

PIPING Process: Liquids Gas

2.

3.

Brown Light Green

Steam/condensate

White

Flushing oil

Brown

Fuel gas/fuel oil

Yellow

Heat transfer fluid ("hot oil")

Brown

Cooling water

Green

Instrument air/tool air

Blue

Nitrogen

Orange

Relief/drain/slops

Black

General purpose

Purple

Fire-fighting water

Red

Category 1 Valves

Yellow

SEWERS, TRENCHES AND TRUNKING Surface water sewer

Beige

Oil contaminated sewer

Black

Cooling water sewer

Green

Electric cable trench

Light Blue

Instrument cable trenches and trunking

Pink

EQUIPMENT, STEEL, CONCRETE AND MAINTENANCE FACILITIES Structural steel

Steel blue

Concrete

Light grey

Mechanical equipment

Dark grey

Electrical equipment

Green

Hoisting beams, davits and other typical fixed maintenance facilities/equipment

Yellow

Equipment (not approved)

Red

Equipment (Approved for location)

Blue

Equipment (Approved for construction)

Green

Safety routes and major access ways

Red

HVAC Systems

White

For all other items, the choice of the colour coding is at the discretion of the Contractor.

DEP 30.10.05.11-Gen. February 2012 Page 31 APPENDIX II

CHECKLIST FOR THE MODEL REVIEW

In this appendix, checkpoints are given for the review of a 3D-CAD model. The checklist will help to improve quality and to identify and eliminate potentially hazardous situations. The checklist shall be read in close consultation with the appropriate project design specifications. The scope of this checklist is applicable to oil refineries, chemical plants, gas plants, exploration and production facilities (onshore and offshore), supply/marketing installations and to specific items such as storage facilities and/or jetties, road/rail loading facilities and complicated manifolds. The checklist is comprehensive but should not be considered to be fully exhaustive. 1.

GENERAL SAFETY AND OPERABIL ITY

1.1

Consider all equipment with respect to its human factors engineering aspects. This includes accessibility, operability and maintenance as well as safety. This applies in particular for accessibility to pump suction and discharge valves and motor operated valves.

1.2

Check proper escape routes from elevated equipment and all platforms. Check that at least two exits are present on every platform with a blind length of over 7 m (23 ft) long. This applies for platforms at structures, around and underneath air-cooled heat exchangers, vessels, on top of furnaces and frequently used working areas by maintenance. Have ladders and staircases been installed on the outside of structures?

1.3

Check that there are no obstructions in the path of escape ways and that escapes ways are as straight as practical. Ensure the exit is directed away from a process area. All staircases should route at ground level to an open area to allow an unobstructed escape way.

1.4

Check that there are no head knockers, shin splitters or tripping hazards.

1.5

Are remote shutdown panels of Remotely Operated Valves (ROVs) and depressuring valves installed at safe distances and can they be easily reached in case of emergency? Can the equipment concerned be seen from these locations?

1.6

Check for proper smooth connections between platforms and table tops.

1.7

Are emergency/smothering steam headers at a safe distance from the equipment to be protected, e.g. in hydrogen service or furnaces?

1.8

Check that operators manipulating drain valves of open drain systems can see the drained effluent. Provide tundishes as required.

1.9

Check that water seals trapped in goosenecks can be displaced by hydrocarbons, i.e. ensure enough static head of oil is available.

1.10

Check if utility stations have been provided at the main operational platforms, especially at columns operating at high temperatures, so that steam lances can be connected to tackle small leaks

1.11

Have platforms been provided at places where work is expected during shutdowns? Consider also access to spading at those places where scaffolding would be a nuisance, expensive or unsafe. (In such cases install additional platforms or adapt existing platforms). Platforms large enough shall be sufficient strong to carry the additional weight if they are used to store spades.

1.12

Check that there are no open sewer pits near hot pumps, furnaces, etc.

Y

N

NA


1.13

Check that steam exhaust cannot cause personnel hazards, either from spraying droplets of hot water or by causing icy or wet surfaces.

1.14

Are steam rings provided where specified?

1.15

Be alert for the possibility of relative movement between connected equipment (e.g. due to different thermal expansion or wind load).

1.16

Check that inlet valves of silencers on steam pipes for warming up or start up are operable in a safe manner without risk of pouring hot condensate from the silencer outlet on the operator below.

1.17

Are hot and cold pipes and surfaces near walkways properly insulated for personnel protection?

1.18

Check that the suction of the air blower of an analyser house or control room is taken from a non-hazardous area.

1.19

Are hoisting devices provided for parts that weight in excess of the manual handling requirements?

2

FIRE PREVENTION AND SAFETY EQUIPMENT

2.1

Check the accessibility of the unit for manual fire-fighting operations.

2.2

Can fire water headers be safely accessed?

2.3

Can a fire truck manoeuvre easily?

2.4

Can all locations be reached by a fire truck if one road is blocked?

2.5

Fire-risk pumps handling liquids above their auto-ignition temperature or handling very light liquids such as propane and butane shall be located: −

in the open;

−

in non-congested areas;

−

− −

at least 3 m (10 ft) from pipe racks and major process structures; so that they are accessible for fire fighting; so that escalation of a possible pool fire from, e.g. a seal failure, is prevented

2.6

Only pumps handling burnable liquids below their auto-ignition temperature may be placed in between a pipe rack and equipment like columns. These pumps should be 3 m (10 ft) away from pipe racks and major process structures and accessible for fire fighting.

2.7

Only pumps handling non-flammable liquids may be placed under pipe racks or structures.

2.8

Can hot pumps be properly protected by fire water spray systems or monitors?

2.9

Check location and protection of fire hydrants (add protection bollards), fixed, mobile and portable fire fighting equipment. Consider this in relation to the equipment to be protected and the likelihood of a fire.

2.10

Check presence of fireproofing of steel structures with respect to credible fires. Protect vessels, columns, flare headers, main pipe racks, if required.

Y

N

NA


2.11

Check whether the layout of water spray pipes and nozzles is adequate to cool LPG vessels.

2.12

Are fire detectors and tubing present on hot pumps and LPG pumps?

2.13

Are detectors for fire, gas, smoke and H2S strategically located?

2.14

Are warning and alarm lights for fire, gas, smoke and H2S strategically located?

2.15

Are fire water deluge manifolds safely located in relation to the equipment they protect?

2.16

Are TV cameras for plant monitoring strategically located to enable a good view of the high risk areas?

2.17

Check if emergency showers and eye wash showers are strategically located, e.g. near equipment handling caustic, ammonia, Adip and aggressive chemicals. Valves are not allowed between the main header and the safety equipment.

2.18

Check the flange orientation of liquid full LPG systems.

3

PIPING

3.1

Is piping entering and leaving the plant logically grouped together at the battery limit?

3.2

Are valves, spading positions, flushing and draining and instrument connections properly located, in relation to normal operations as well as shutdowns? Take special care of manifolds relief valves and large control valves. If spades have been provided, is there sufficient storage area when the spacers are installed? If spectacle blinds are fitted, are they accessible and can they be turned safely? Consider additional or adapted platforms where applicable.

3.3

Has the number of flanges been minimised? This is valid especially in systems above auto-ignition temperature and with toxic materials.

3.4

Check the elevation of piping and its clearance to walkways and maintenance equipment (e.g. lifting equipment). Avoid head bumpers.

3.5

Are start-up and circulation pipes short? Have dead ends been avoided? Can the system be flushed and drained?

3.6

Do vapour pipes, including steam pipes, freely branch off from the top of main pipes?

3.7

Can piping subject to thermal expansion indeed expand? Check that nozzles and branches (e.g. instruments) on expanding piping do not touch obstructions, such as support beams.

3.8

Look for pockets in vapour pipes where condensation may occur. Has external heating been applied on those pockets which cannot be avoided?

3.9

Are long small diameter pipes (e.g. instrument impulse pipes) supported properly to prevent breakage due to vibration?

3.10

Check for adequate space and jacking facilities to remove man-hole covers, especially for those with inserts.

Y

N

NA


3.11

Pipes should not pass through table tops. Where this cannot be avoided, ensure a protective kerb is provided around the open area to prevent any rainwater or oil entering the area below. All rain water disposal pipes from a table top shall be extended to ground level.

3.12

Have dead end sections been avoided, e.g. in steam and water pipes and in pipes with high pour point material?

3.13

Has piping been designed for ease of drainage and/or venting?

3.14

Check the position of eccentric reducers. Normally, the straight part is on the bottom of horizontal pipes, except in pump suction pipes where vapour pockets may cause cavitation of the pump.

3.15

Do compressor suction pipes slope towards the knock-out drum? Each low point of the compressor suction should have a low point drain.

3.16

Check that small bore cooling water pipes emerge from the top of the header.

3.17

Are stripping steam pipes short and horizontal, or sloping from the last valve?

3.18

Verify that two-phase flow vertical piping has been checked for flow stability, also for the turndown case.

3.19

Check absorber gas feed inlets for pockets near the inlet to avoid absorbent entering the gas inlet pipe.

3.20

Is piping with instrument connections positioned such that these connections are easily accessible? Is the measurement point in the correct process location? Have the necessary platforms and walkways been provided?

3.21

Is there adequate straight length upstream and downstream of a flow meter or orifice flange?

3.22

Is there sufficient space around an ultrasonic flow meter to allow proper installation of the flow meter sensor in the horizontal plane without touching adjacent pipes?

3.23

Is the straight length sufficient on inlet pipes as specified at column inlets, knock out vessels and cyclones?

3.24

Are maximum angles with the vertical as specified for piping containing solids adhered to?

3.25

Have special provisions for commissioning and initial start-up been properly addressed? (e.g. temporary large blow spools and silencers).

3.26

Has piping been checked for water hammer where applicable?

3.27

Check for appropriate clearance around flanges, piping and valves. As per DEP 31.38.01.11-Gen. and DEP 30.00.60.13-Gen.


4.

VALVES

4.1

Have valves in pipe bridges been avoided as much as possible?

4.2

Check for the presence of chain-operated valves (only allowed in exceptional cases).

4.3

Check that there are no valves installed with the stem pointing downward.

4.4

Are hand wheels easily accessible for operation and not obstructing walkways or platforms? (Consider the stems, especially when in the open position.)

4.5

Are valves for emergency operations operable from grade level? Are valves that need frequent attention easily accessible?

4.6

Check for valves in vertical pipes which may accumulate liquid (e.g. water or condensate).

4.7

Check that control valve assemblies are located at ground level or on the first platform, except when otherwise required for process reasons.

4.8

Has installation of valves outside of platforms been avoided?

4.9

Have check valves or double-block valves been installed in utility connections to process equipment and pipes?

4.10

Have spring-loaded and/or extra block valves been used where valves may freeze up when draining or sampling?

4.11

Check that stripping steam pipes to columns have a drain pipe for condensate removal and a vent pipe near to the column.

4.12

Check that the status of vent and drain valves used for instrument maintenance or for decommissioning of plant during turnarounds, as well as those used for operational venting and draining shall be clearly visible from the operator vantage point at access platforms and walkways.

5.

HEAT EXCHANGERS AND REBOILERS

5.1

Is the piping arrangement and supporting acceptable with respect to removal of shell and channel covers as well as the withdrawal of tube bundles? Consider the removal of inlet and outlet piping. Has the bundle pulling device sufficient plot space?

5.2

Check whether bundles can be pulled and lowered safely from platforms and stacked exchanger arrangements.

5.3

Check stacked heat exchangers for the possibility of oil spills on hot heat exchangers or other equipment beneath, especially during maintenance work. In this case, consider a large oil collecting funnel underneath, or check the possibility to take both out of service.

5.4

Check if the drain and vent valves are correctly located as specified on the PEFS, hence drains at lowest points and close to the block valves if so specified.

5.5

Check whether cranes, bundle pulling equipment and cars can enter for pulling and transportation of bundles.

5.6

Check whether heat exchangers can be cleaned in situ. Are the required provisions present (e.g. valves, cleaning pipes, etc.)?

Y

N

NA

Y

N

NA


5.7

Check that exchangers in LPG service have been provided on the water outlet side with a vent pipe to a safe location to allow gas to escape in case of tube leak.

6.

PUMPS AND COMPRESSORS

6.1

Is valving around pumps and compressors accessible and operable? Note that the hook-up around pumps provided with seal oil pipes, steam pipes, flush oil, steam tracing, etc. needs considerable plot space. These small size support pipes may not been indicated in the model. Ensure adequate pump accessibility. Ensure start/stop poles are not obstructed.

6.2

Can the pump and compressor safely be handled for maintenance such as filter pulling? Pay special attention to spading-off possibilities and draining of the casing and the strainer.

6.3

Is removal of the pump and the electric motor practical?

6.4

Ensure that steam tracing around the suction and discharge pipes can be dismantled to allow pump removal.

6.5

Is the flow in suction piping smooth? Check for the required straight length of the suction pipe for double-suction pumps.

6.6

Have high points in pump suction pipes been avoided?

6.7

Check volumes which must be drained when a filter or the pump needs to be opened. If the volume is very large, enlarge the size of drain valves to achieve a reasonable draining time. Also check that the drain piping of filters and casing is short and straight.

6.8

For pumps with a vertical suction pipe and an elevated strainer, check that opening of such a strainer does not result in spilling flammable liquid and possible ignition on nearby hot surfaces.

6.9

Are pump priming facilities adequate? Is the vent valve at the highest point at discharge and suction side?

6.10

Is location of the local compressor panel logical?

6.11

Are compressor seal oil tanks provided with their vents to the atmosphere at a safe location?

6.12

Are lube oil storage drums properly protected against ingress of rain wate r and is the storage area properly drained?

6.13

Are compressor recycle pipes self-draining on both sides of the recycle control valve?

6.14

Are compressors with bottom inlet pipes at the suction provided with liquid drains to a closed system?

6.15

Is instrumentation (e.g. panels) easily accessible for maintenance?

6.16

Has plant vibration been considered in the location of instruments and electrical equipment?

6.17

Is there space for cranes to enter and manoeuvre?

6.18

Check lighting around level gauges, pumps and compressors

Y

N

NA


7.

FURNACES AND BOILERS

7.1

Check that suction of air blowers is taken from a non-hazardous area.

7.2

Check that piping does not obstruct observation windows, access doors, header box covers, etc.

7.3

Is space available for withdrawing and cleaning tubes? Is there space for cranes to enter and manoeuvre?

7.4

Is piping at burners arranged in such a way that insertion and removal of ignitors and burner guns is not hampered?

7.5

With regard to the safety of fuel systems: −

−

−

Y

N

NA

Y

N

NA

Are heavy fuel and LBF (low boiling fuel) systems sufficiently segregated? Are adequate provisions made to prevent liquid fuels from entering atomising steam and steam-out pipes? Are low-points in fuel gas pipes avoided between the fuel gas knock-out vessel and the burners or has tracing been provided?

Are locations of flame arrestors, straight pipe lengths, etc. of low pressure and waste gas in accordance with specifications? 7.6

Are emergency/smothering steam headers at a safe distance?

7.7

Make sure that dry emergency or smothering steam is made available, with: −

outlet branches positioned on top of mains;

−

steam pipes without pockets;

sufficient steam traps and drain points provided. 7.8

On manually-started furnaces, are fuel valves of fuel oil and fuel gas within reach when looking at the burners through the observation windows?

7.9

Is the emergency shutdown switch at a safe location?

7.10

For multiple furnaces: check for a logical and clear layout of each furnace and its local start-up panel.

7.11

Can a furnace be spaded off at its flue gas duct for furnace entrance and repair? This is required when multiple furnaces are connected to a common flue gas duct and one of the furnaces is required to continue to operate.

8.

VESSELS AND COLUMNS

8.1

Check for unnecessary dedicated drain piping (e.g. where draining a vessel or column to grade can be done via existing piping such as drains of pumps).

8.2

Check that manholes are within reach of hoisting equipment? Ensure proper space on platforms for turning the manhole covers and for entering equipment.

8.3

Are instrument tappings and local instruments and level glasses readily accessible? Note that a levelglass on a vessel or column actually may protrude 500 mm (20 in) into the platform area and thus form an unacceptable obstruction.

8.4

Check that instrument support poles, such as those used for pressure transmitters, are not obstructing a walkway of a platform around a column.


8.5

Has insulation for personnel protection been provided? Check especially hot vapour and product pipes which can be easily touched from platforms.

8.6

Can the pipes follow the expansion of the equipment when heating up and cooling down? Pay special attention to supports on both hot and cold structures.

8.7

Check free movement of platforms (thermal expansion).

8.8

Check if specified elevations of vessels and columns on PEFS are adhered to.

8.9

Check that the barometric seals of vacuum equipment are at the specified height. This also applies for relative elevations of vessels belonging to a vacuum system.

8.10

For columns with structured packing, ensure there is a steam and water hose connection point nearby to fight any spontaneous fire when opening the manholes.

9.

RELIEF SYSTEMS: FLARES AND VENT SYSTEMS

9.1

Flare pipes shall have no pockets and shall slope continuously to the flare knock-out drum. If a low point is unavoidable, ensure a drain with adequate size is connected to a drain vessel.

9.2

Are flare headers provided with an end blind flange or manhole entry point to allow for inspection and internal cleaning?

9.3

If a platform is installed for spading a part of the flare pipe whilst the main flare pipe is still in use, ensure that there is enough space to do the work. Check that there is a proper escape way from this platform.

9.4

Check that inlet pipes to relief valves are self-draining into process equipment. Relief valves should be located on the main process header.

9.5

Check that outlet pipes from relief valves are self-draining into the flare header. An exception may be made for liquid (DN 25 × DN 25) thermal relief valves which do not need to be self-draining on both sides if the pipes would become too long. Check that connections are made on top or on the side of the flare header. Ensure that process relief valves and process thermal relief valves are not routed to grade. They should end in a closed system.

9.6

Check the accessibility of relief valves sets for maintenance and inspection. Have relief valves been installed at proper elevations relative to the flare header? All relief valves should be accessible for removal (by hoisting equipment if necessary).

9.7

Is safety/relief valve piping as short as possible when discharging into a closed system?

9.8

Check relief valves discharging to atmosphere for safe location and direction. Ensure that hot equipment is not located below discharge points to the atmosphere if any hydrocarbons can be released. For a waste gas seal vessel, pay special attention to this check.

9.9

Can relief valves be blocked-in and drained?

9.10

Check relief valve outlet pipe arrangements such that supports can be provided to cope with reaction forces.

9.11

Is reactor vent gas safely routed during a regeneration?

Y

N

NA


9.12

Is the distance from the flame arrestor to the vent outlet as specified? Ensure that flame arrestors in pipes to the atmosphere can be accessed for removal and maintenance.

9.13

Check that the spindles of flare main block valves, if gate valves, are in a horizontal position. This prevents a blocked flare pipe if the wedge should fall down.

10.

OIL MOVEMENTS In addition to the above checkpoints, the following shall apply for oil movements installations.

10.1

Has the tankfarm been designed in accordance with the agreed specifications, inclusive of separation distances?

10.2

LPG storage: are safety requirements fulfilled, including distances, valves, piping, pressure relief provisions, civil aspects?

10.3

Tankfarms: is the layout logical in relation to battery limits, pipe tracks, blending and loading area?

10.4

Are tanks and bund areas accessible for fire fighting equipment?

10.5

Are tanks draining to an environmentally acceptable system?

10.6

Storage tanks with a blanketing system: is layout adequate, including its vapour routing?

10.7

Vapour recovery systems: consider layout and maintenance aspects.

10.8

Jetties: are adequate working envelopes provided for hoses and loading arms and is the width of the jetty sufficient for the required equipment?

10.9

For tankfarms and pipe tracks: can rainwater and spilled oil be drained adequately?

10.10

Consider the elevation of movements facilities in case of large oil spills to surrounding plants.

10.11

For product blending facilities: see (3.3), (3.4) and (3.6).

10.12

For flares and vent pipes in movements area: see (3.9).

11.

ENVIRONMENTAL CHECKS

11.1

Check if any process liquid drained from equipment can be handled in an environmentally acceptable manner, in line with general approach of closed loops for liquid draining or vents. If required install funnels to the oil collecting system.

11.2

Check drainage from pump casings and pump strainers.

11.3

Check drainage from process filters and coalescers.

11.4

Check drainage from fuel filters of furnaces.

11.5

Are drains from sample points of plants and storage tanks minimised by, for example, closed loops?

11.6

Check drainage from instruments in analyser houses.

Y

N

NA

Y

N

NA


11.7

Check drainage from heat exchangers when opened for bundle cleaning or repairs. Consider also the effect of liquid spillage when opening both heads as well as when pulling the bundle.

11.8

Check drainage of sour or spent seal and lube oils from compressors.

11.9

Check drainage from pipes at the battery limit prior to spading the unit.

11.10

Check vent to atmosphere from an analyser house.

11.11

Check that liquid collected in an open oil collecting pit inside the unit is prevented from evaporation, e.g. by covering with a closed plate.

11.12

Check where vents of seal chambers of reciprocating compressors are routed to.

11.13

Check that unloading and storage of chemicals, additives, caustic, ammonia, etc. can be carried out without environmental impact.

11.14

Check that the distance around plants is in accordance with any local regulations, including noise limitations.

DEP 30.10.05.11-GEN Feb 2012 3D Model Review.

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