Scope of Work for 3D-Model Procedure

Sarcheshmeh Flash Furnace Smelting Project Document No: Contract No: 4047 DOCUMENT TITLE:

Rev.

418/200-D00-M1-020 0A Scope Of Work For 3D-Model Procedure

Area No. : 200 Date: 02 Nov 2011

Page 1 of 31

SCOPE OF WORK FOR 3D-MODEL PROCEDURE

0A

02 Nov 2011

Issued for Review

M.G

M.S

H.M

Rev.

Date

Purpose of Issue

PREPARED

CHECKED

APPROVED

Sarcheshmeh Flash Furnace Smelting Project Document No: Contract No: 4047


DOCUMENT TITLE:

Sheet No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

00 x x x x x x x x x x x x x x x x x x x x x x x x

26 27 28

x x x

25

x

Rev.

01

Rev.

02

Sheet No. 29 30 31

Revision Index Rev. 00 01 02 x x x

Sheet No.


Rev.

Page 2 of 31


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TABLE OF CONTENTS 1 2 2.1 2.2 2.3 2.4 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 5 5.1 6 6.1 6.2 6.3 6.4 6.5

GENERAL .................................................................. ERROR! BOOKMARK NOT DEFINED. ABBREVIATIONS .......................................................................................................... 4 EPY ............................................................................................................................. 4 CONTRACTOR DEPARTMENTS .............................................................................................. 4 CONTRACTOR PROJECT ORGANIZATION ................................................................................. 5 SUBCONTRACTOR ABBREVIATIONS ……………………………………... 4 ORGANIZATION AND RESPONSIBILITIES ....................................................................... 5 KEY PERSONNEL ............................................................................................................... 5 FUNCTION AND RESPONSIBILITY ............................................................................................ 6 WORK PROCESS ........................................................................................................... 7 3D MODEL PREPARATION .................................................................................................. 7 MODEL REVIEW PHASE ...................................................................................................... 7 CHECKING FOR INTERNAL REVIEW ....................................................................................... 12 COMMENT AND APPROVAL FOR INTERNAL REVIEW .................................................................. 13 COMMENTS, CHECKING AND APPROVAL FOR EPY REVIEW ........................................................ 13 RECORDS ................................................................................................................... 14 COMMENTS SHEETS ........................................................................................................ 14 LIST OF ATTACHMENTS .............................................................................................. 14 ATTACHMENT-I: 3D MODEL CONTENT FOR REVIEW .................................................... 11 ATTACHMENT-II: COMPUTER INTERNAL MODEL REVIEW – COMMENT SHEET ............................. 15 ATTACHMENT-III: COMPUTER EPY’S MODEL REVIEW – COMMENT SHEET ................................ 16 ATTACHMENT-IV: MODEL REVIEW AGENDA ..................................................................... 17 ATTACHMENT-V: CHECK LISTS ................................................................................. 21



DOCUMENT TITLE:

1 1.1

Rev.


Page 4 of 31

GEENERAL INTRODUCTION Construction on EPC basis of Flash Smelter Furnace Sarcheshmeh Copper Complex being located at 50 km west of Sarcheshmeh Kerman and 30 km east from Shahr Babak city at Kerman province, Iran, with the steady production capacity of 875 ton per day Cathodic copper production with the technical documents and specifications and conditions mentioned in the project documents. Including of basic engineering review, detail engineering, site engineering, material supply (foreign / local), manufacturing / inspection, packing, insurance covering, site fabrication, all construction activities including of civil works, equipment erections & test, pre-commissioning, test performance, client personnel training, 2 years spare parts supply for operation, consumable material supply for 12 month operation, supervision on operation for 6 month.

1.2

SCOPE OF WORK This Procedure defines the process for preparation, checking, review and approval of the computerised design (3D) model together with the steps to be followed for the internal and EPY reviews of the 3D model for the Project development.

2

ABBREVIATIONS

2.1

EPY CLIENT, of the project and the relative team of PMC (Project Management Consulting) involved in the design management activities.

2.2

Contractor Departments FF

Fire Fighting

HSE

Health and Safety Environmental Department

CIV

Civil Engineering

CSO

Construction

ELE

Electrical Systems and Telecommunications



DOCUMENT TITLE:

2.3

2.4

Rev.

MAPAF

Machinery, Package and Furnaces

MODEL

3D Model Department

I&C

Instrumentation and Automation Systems

PIP

Plant Layout and Piping Engineering

CLIENT

Client

PR

Process engineering

EQ

Equipment & Mechanical department

AR

Architect department

SE

Structure department


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Contractor Project Organization PM

Project Manager

TM

Technical Manager

DTM Design)

Deputy Technical Manager (Process, Equipment, Plant

SE

System Engineer

PQC

Project Quality Co-ordinator

PSL

Project Specialist Leader

T3D

3D Modeller team

Subcontractor Abbreviations HRS Engineers

HAMANDISHAN RAH SANAAT Consultant

3

ORGANIZATION AND RESPONSIBILITIES

3.1

Key personnel 

PM


Rev.



Page 6 of 31

Has the overall responsibility to ensure that the PDMS Design Model are produced in accordance with the Project Schedule and Procedures. 

TM Has the responsibility for the overall technical content of the model.



PIP PSL Has the responsibility for the daily production and overall co-ordination of 3D model development, review and approval.



T3D - 3D Modeller Team Has responsibility to create the 3D Model and include in the system all the design information developed by the Technical Departments. Has responsibility to produce the final document to be submitted to the originator department for final comments and official issue.

3.2

Function and responsibility 3.2.1

Internal Model Review

 TM/SE and PSL PIP shall organize and lead the Model Review.  Each discipline Lead Engineer shall ensure that the information transferred to the 3D Modeller Team has reached the design requirements and properly modelled the component according to the stage of development as defined in the attachment I. 3.2.2 EPY’s Review  

TM/SE shall organize and lead the Model Review with the PSL PIP that is the reference point to clarify any query raised by EPY’s review. Each discipline’s Lead Engineer or his nominate Engineer shall participate in the review meeting if/when requested by TM/SE.


4

Rev.



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WORK PROCESS 4.1

3D Model Preparation 4.1.1 The 3D Model includes all the information necessary to define the level of completion that is to be reached developing detail plant engineering according to the contents defined in attachment I. 4.1.2 Plant layout design is based on the use of 3dimensional software program (PDMS), as specified in the contractual documents. 4.1.3 All the information shall be input in the 3D Model system by the 3D Modeller Team (T3D) according to the design developed by each technical department (ELE, I&C, CIV, etc.). The matrix of responsibilities for each discipline and task information is defined in attachment I. Also List of Procedures & Instructions for 3D-Modeling will be submitted from Mobina Co. (See Document Number: INS-3DM-LIST) 4.1.4 The relevant work process is characterized by the continuous incorporation of information into the model, in strict correlation with the Project development.

4.2

Model Review Phase 4.2.1. The 3D Model work process will be formally reviewed at Three different phases (30%, 60%, 90% Model Review) corresponding to the achievement of programmed objectives, based on the standard project schedule. 4.2.2. Due to the huge review work required by the Sarcheshmeh Project each formal Model review will be preceded by a continuous Model review phase (NavisWorks is the 3D tool available to each department and EPY’s staff). 4.2.3. During the continuous review phases both EPY and each technical Department will be involved in the 3D Model exploration and will be in condition to send their own comments, if any, to the T3D representative.


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4.2.4. All the comments will be collected and recorded by the T3D representative who will decide with TM/SE if to close the issue or to discuss within the next formal Model review. EPY will provide to convey its comments to the T3D representative only through its own (unique) representative. 4.2.5. Upon completion of the continuous review phases, the model will be checked and formally approved to consolidate its content and to authorize the development of subsequent activities. 4.2.6. The work flow is shown in the following flow chart:


Rev.


DOCUMENT TITLE:


Work Flow of 3D Modeling Review

Comments From EPY

Model Start

EPY’s Representative

T3D

Comments From Tecnical Dpts

30% Model Review Comments from EPY


T3D


60% Model Review Comments from EPY


(Continuous Review) T3D


90% Model Review

Comments from EPY (

) T3D

EPY’s Representative Comments From Tecnical Dpts

Model Finish

Page 9 of 31


Rev.



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The objectives of each phase are as follows: 

Preliminary phase: 30% complete Preparation of the model of Process Units for equipment and building locations, main structures (single lines design) and, if necessary, for large bore critical piping (above 24”), whose routing may affect the Plot Plan layout. For Utilities Units only a box shall be modeled in order to define the Packages location. Major underground systems; distribution headers (i.e. cooling water) main sewer drainage and wide trench should be modeled only in consideration to the layout impact. The objective in this phase is to verify the Plot Plan.



Intermediate Phase: ≥ 60% complete. After the Plot Plan has been consolidated, detailed engineering will start and the model will be enhanced with: major piping upon the basis of all the information available on P&ID’s (drowned by HAZOP analysis) as manual valves, instrument valves, drainage, etc, in accordance with operation and maintenance required. Approximately 30% of piping model completion: all piping indicated in PFD and all underground piping. Equipment nozzles orientation and package unit have to be modeled. Moreover structures have to be modeled in accordance with civil drawings, including ladders, platforms and handrail required for access and maintenance equipment, valves and instrumentation. At this stage finalization of all underground elements is included; pipes, electrical and instrumentation cables, foundation in accordance with the available civil drawings. In this phase there is continuous interaction of all the involved Departments, which is aimed at resolving any problem related to the correct interpretation of P&ID’s, to remove potential interference between the systems, and to optimize detailed plant layout engineering.


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The scope in this phase is to ensure that all the process requirements are in compliance with contractual requirements for accessibility, operability, maintenance, and space for future upgrade. Moreover, comments starting from 30% Model Review shall be incorporated. 

Final Phase: ≥ 90% complete The model will be completed by the incorporation of all agreed comments at the intermediate phase and the remaining elements: approximately 70% of piping model completion (i.e. all 2” and larger piping shown on P&ID and distribution diagram), pipes supports, field instrument, lighting, and communication devices location, the addition safety elements as shower and eye-washers, firefighting equipment, safety device location. Moreover, interference checks can be performed to verify piping clearances from structural steel, other pipes, etc. The scope at this phase is to insure that the model contains sufficient information for the final check of material requirements and the production of final documentation for construction.



Final Report Implementation of 90% design review comments and final report acceptance.

The content of the model in each phase of completion is summarized in attachment I. 4.2.7. EPY Review could require different number of phases at different percentage of completion, in this way a revision of the attachment I shall be prepared for the specific project and submitted to Client for approval.


4.3

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Checking for Internal Review Methods for checking differ in relation to the phase of model preparation. The check list provided in attachment II shall form the basis of the review. This check list should not be considered to be fully exhaustive; any additional check can be implemented per project. 4.3.1.        

The preliminary phase is aimed at review the follow information: Freeze of equipment lay-out in plan and elevation Construction and erection consideration Safety distance Accessibility Operability Maintenance accessibility and device Economized of design Conceptual piping lay-out for process consideration

4.3.2. The intermediate phase is aimed at check and freeze the follow information:  Construction and erection  Safety distance  Accessibility  Operability  Maintenance accessibility and device  Economized of design  Piping lay-out routing according process requirements  Validate compliance with the project scope and standards 4.3.3.

The final phase review is performed in a similar manner to the intermediate review as detailed in 4.3.2., incorporating the entire comment arisen in the previous phases.


4.4

Rev.



Page 13 of 31

Comment and approval for Internal Review Extensive interference checking shall be performed involving all disciplines prior to each formal design review to ensure that all known clashes have been cleared.  Using NavisWorks, the involved technical departments will perform separate review sessions, tag and photograph each comment raised from internal department review according to the methodology indicated in attachment III.  Model review sessions dedicated to each discipline if required by TM/SE (ELE, I&C, CIV, etc.) are prepared and in them are collected the comments and a mono disciplinary Minute of Meeting is issued according to attachment III. All the comments shall be recorded and tagged as per chapter 5. Each discipline engineer shall study and offer countermeasure to solve the comments arisen during the review and, in case of interdisciplinary consequence, the solution shall be agreed under the TM coordination.

4.5

Comments, Checking and Approval for EPY Review EPY Review o The TM with the PIP PSL support will schedule the official review meeting with EPY, giving notice to the EPY at least 2 weeks in advance notice in order to prepare personnel and travel authorizations. o The TM will produce the following model review aid to be issued to all review participants:  Model Review Agenda  List of Predefined Model Views  Comment sheets.


5 5.1

Rev.



Page 14 of 31

o 2 sets of the following drawings shall be available in the model review room:  P&ID’s  Plot Plans. RECORDS Comments Sheets 5.1.1 During the internal or EPY model review – both continuous and formal - the proper form shall be filled by T3D representative with all the comments arisen during the reviews. 5.1.2 Each comment – not yet closed before formal review - will be discussed during the meeting and the competence for the action shall be defined and agreed. 5.1.3 Both comments sent to T3D representative and comments arisen during the reviews shall be tagged with a progressive number and the originator code. 5.1.4 All the approved comments have to be incorporated into an electronic database trough the relative tag number and the relative unit, the tag text and the additional note for an appropriate upgrade, the component department, the progress status and the due date. The information is completed with a link to the picture extracted by the 3D model 5.1.5 The electronic files of the model will be handed over to completion Home Office Design Activities

6

LIST OF ATTACHMENTS 6.1 ATTACHMENT-I: (ATTACHED FILE)

3D

MODEL

CONTENT

FOR

REVIEW

6.2 ATTACHMENT-II: Computer Internal Model Review – Comment sheet (ATTACHED FILE) 6.3 ATTACHMENT-III: Computer EPY’S Model Review – Comment sheet (ATTACHED FILE) 6.4 ATTACHMENT-IV: Model Review Agenda (ATTACHED FILE) 6.5 ATTACHMENT-V: CHECK LISTS (ATTACHED FILE)


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ATTACHMENT-I: 3D MODEL CONTENT FOR REVIEW Ser. No. 1 1-1 1-1-1 1-1-2 1-1-3 1-1-4 1-1-5 1-1-6 1-1-7 1-1-8 1-2 1-2-1 1-2-2 1-2-3 1-2-4 1-2-5 1-2-6 1-2-7 1-3 1-3-1 1-3-2 1-3-3 1-3-4 1-3-5 1-3-6 1-3-7 1-3-8 1-4 1-4-1 1-4-2 1-4-3 1-4-4 1-4-5 1-5 1-5-1 1-5-2 1-5-3 1-5-4 1-5-5 1-5-6 1-5-7 1-6 1-6-1 1-6-2 1-6-3 1-6-4 1-6-5

Description

Modeli ng

Equipment (1) Fixes FSF Outline of FSF Nozzle & manhole Ladder, platform, stairs Davit Lifting lug Trays and other internals Insulation Obstructions & reserved volume ESP Outline of ESP Nozzle & manhole Ladder, platform, stairs Davit Lifting lug Insulation Obstructions & reserved volume Vessels Outline of Vessel Nozzle & manhole Ladder, platform, stairs Davit Lifting lug Internals Insulation Obstructions & reserved volume Heat exchangers Outline of heat exchangers Nozzle Ladder , platform, stairs Insulation Tube bundle maintenance space Tanks, Bins , Loss In Weights (LIW) Outline of tanks Nozzle & manhole Ladder, platform, stairs Insulation Obstructions & reserved volume Davit Fire water rings Filters (Bag filters , … ) , Vibrating Screens and Crushers Outline of filters Nozzle Ladder, platform, stairs Davit Insulation

First Review

B B B D D D B B



B B B D D B B



B B B D D D B B



B B B B B





2nd Review

Final Review

      

     

       

 

B B B D B



     

   

EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ

  

B B B B B D D

Related to

EQ EQ EQ EQ EQ EQ FF & PIP EQ EQ EQ EQ EQ

Remark

Note 1 Notes 4,6

Note 5 Note 5

Note 1 Notes 4,6

Note 5 Note 5

Note 1 Note 4

Note 5 Note 5

Note 1 Notes 4,6 Note 5

Note 1 Notes 4,6 Note 5 Note 5

Note 1 Notes 4,6 Note 5

Sarcheshmeh Flash Furnace Smelting Project Document No: Contract No: 4047 DOCUMENT TITLE: Ser. No.

Rev.

418/200-D00-M1-020 0A Scope Of Work For 3D-Model Procedure Description

Modeli ng B D

First Review

2nd Review 

1-6-6 1-6-7 2 2-1 2-1-1 2-1-2 2-1-3 2-1-4 2-1-5 2-1-6 2-1-7 2-2 2-2-1 2-2-2 2-2-3 2-2-4 2-3 2-3-1 2-3-2 2-3-3 2-3-4 2-3-5 2-3-6 2-3-7 2-4 2-4-1 2-4-2 2-4-3 2-4-4 3 3-1 3-2 3-3 3-4 3-5 4 4-1 4-2 4-3 4-4

Obstructions & reserved volume Lifting lug Equipment (2) Rotating machines Large pumps  Outline of pumps B  Nozzle B Local panels & terminal boxes (if any) B Outline of auxiliary units D Auxiliary piping within vendor scope D Enclosure D Sun Cover B Small pumps  Outline of pumps B  Nozzle D Enclosure D Local panels & terminal boxes (if any) B Compressors, blowers, fans and drivers  Outline of machines B  Outline of auxiliary units B  Nozzle B Local panels & terminal boxes (if any) B Internal piping in unit D Enclosure B  Maintenance space B Cooling towers  Outline Cooling Tower B  Ladder, platform, stairs B  Nozzle D  Maintenance space B Equipment (3) Package unit  Outline of package unit B  Tie -in Nozzle B Piping in the unit D  Instrument component in the unit D Local panels & terminal boxes (if any) B Equipment (4) WHB ,Burners , Anode Furnaces and Incinerators, Steam Dryer  Outline of Fired heater and Boilers B  Access and peep doors D  Nozzle B  Ladder, platform, stairs B

4-5 4-6 4-7 5 5-1 5-2 5-3 6 6-1

Outline of burner assembly Duct ,dampers, lever Local panels Equipment (5) Instrument Local instruments on equipment Pressure instruments on equipment Temperature instruments on equipment Equipment (6) Others (outline) Eye washer and shower

D D D

Date: 02 Nov 2011 Final Review



Page 16 of 31 Remark



Related to EQ EQ

    

EQ EQ EQ EQ EQ EQ EQ

Note 4 Note 1 Note 5

Note 4

 

EQ EQ EQ EQ

  

  

EQ EQ EQ EQ PIP EQ EQ

Note 5

Note 5 Note 4 Note 5 Notes 1,5 Notes 1,5 Note 5 Notes 4,5

EQ EQ EQ EQ

Note 4 Notes 4,6

EQ EQ EQ

Notes 1,4 Notes 1,4,5 Not Applicable Not Applicable Notes 1,5,4

EQ EQ EQ EQ

Note 4



EQ EQ EQ

  

PIP,I&C PIP,I&C PIP,I&C

 

D D D B

Area No. : 200

FF

Notes 1,4 Notes 4,6

Sarcheshmeh Flash Furnace Smelting Project Document No: Contract No: 4047 DOCUMENT TITLE: Ser. No. 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 7 7-1 7-2 7-3 7-4 7-5 8 8-1 8-2 8-3 8-4 8-5 8-6 8-7 9 9-1 9-2 9-3 9-4 9-5 10 10-1 10-2 10-3 10-4 10-5 11 11-1 11-2 11-3 11-4 11-5 12 12-1 12-2 12-3 12-4

Rev.


Fire fighting systems (hydrants, monitors) Ejectors Silencers Conveyers and belt scales Mixers Ductworks Ladles and Launders Miscellaneous Hoods Magnetic separators Cranes and Hoist Casting Wheels Structure (1) Structures and pipe racks Structural frames (steel and concrete) Brace Ladder, platform, stairs Gusset Joists Structure (2) Compressor house Structural frames (steel and concrete) Brace Ladder, platform, stairs Roof Top Table of foundation Permanent crane/rail and hoisting beams and Walls Structure (3) Others Platforms for valves operation Equipment foundation Structure foundation Pipe sleeper Fire proof Civil (1) Landscaping Roads Paving Spill wall Dike Drop out area Civil (2) Under Ground Outline of trenches and pits inside civil unit Outline of duct bank Underground footing Underground manholes Sewerage Architect Buildings & Houses Smelter Office Building Converter Operation building Restaurant Contractor office house

Modeli ng B D D B D D D D D D D D

First Review

B B B D D



B B B B B B D



D B B D D B B B B D B D D D D B B B B

2nd Review            

Area No. : 200 Date: 02 Nov 2011 Final Review

    

     

SE SE SE SE SE

Note 8 Note 8 Notes 4,6,8 (Just Note 8 Note 8

SE SE SE SE SE SE AR

Note 4,8 Note 8 Notes 4,6,8 Note 4,8 Note 4,8 Note 4,8


Note 4 Note 4 Note 4 Note 4



CIV CIV CIV CIV CIV CIV CIV CIV CIV CIV

Note 4 Note 4

AR AR AR AR

Note 4 Note 4 Note 4 Note 4

   

  

   

Remark





 

Related to FF EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ EQ

SE SE SE SE SE

  



Page 17 of 31

Note 4 Note 4

Sarcheshmeh Flash Furnace Smelting Project Document No: Contract No: 4047 DOCUMENT TITLE: Ser. No. 12-5 12-6 12-7 13 13-1 13-2

Rev.


Converter Operation Building Wall Acoustic insulation Electrical Underground Cable Trenches/Duct Banks/Racks and Above Ground Cable Ladders/Trays/Conduits/Racks for Power/Control

Modeli ng B B D

First Review  

2nd Review

B



D



B



13-4 13-5 13-6

Lighting panel Lighting fixtures & Lightning devices Telecommunication Device

D D D

 

14

Instrument Underground Cable Trenches/Duct Banks/Racks and Above Ground Cable Trays/Conduits/Racks for Instrument Cables Junction boxes Local panels Field analyzers (pH meter, conductivity meters, Inline flow meters (orifice flange ,flow nozzle, Flow meter runs, upstream & downstream Restriction orifice Pressure relief valves Control valves with actuators and bypasses Displacement level instrument with external Level switches with external chamber Level gauge (gauge glasses) Bridle (standpipe) for level instruments Pressure switches and differential pressure Pressure gauges Temperature transmitters (in-lines) Thermo elements ( thermocouples and RTDs) Dial thermometers Local signal indicators Instrument Transmitters (mounted on stanchions) Instrument process Lines (impulse lines) Instrument tracing lines Instrument air lines Air manifolds Piping (1) Above ground piping Process & Utility Piping Major Critical Piping NPS 2'' and larger Piping NPS 1-1/2'' and smaller Piping Sampling Piping Line Trap Piping Manifold for steam trace Fire water spray line for equipment

B

                 

Related to AR AR AR

Remark

EE

Note 4


Note 4

EE

Not Applicable

EE EE EE

Not Applicable Not Applicable Not Applicable

I&C


    

I&C I&C I&C PIP I&C PIP PIP PIP PIP PIP PIP PIP I&C PIP PIP PIP PIP I&C I&C PIP I&C PIP I&C

Note 1

    

PIP PIP PIP PIP PIP PIP PIP

  



  

Page 18 of 31

EE 



B D D B D D D D D D D D D D D D D D D D D D D

B D D D D D D

Final Review



Local control stations of motors Substation Building/Transformers/Trans-yards and Busducts/Switchgears/Panels

14-2 14-3 14-4 14-5 14-6 14-7 14-8 14-9 14-10 14-11 14-12 14-13 14-14 14-15 14-16 14-17 14-18 14-19 14-20 14-21 14-22 14-23 14-24 15 15-1 15-2 15-3 15-4 15-5 15-6 15-7 15-8

Date: 02 Nov 2011



13-3

14-1

Area No. : 200

Note 1/4

Sarcheshmeh Flash Furnace Smelting Project Document No: Contract No: 4047 DOCUMENT TITLE: Ser. No.

Rev.


Modeli ng D D D

First Review

15-9 Fuel gas line around heater burner 15-10 Hose Station 15-11 Auxiliary Piping for Machines (outside vendor's 16 Piping (2) Underground piping 16-1 Cooling water, chilled water, potable water, B 16-2 Fire water B 16-3 Closed Drains, Oily Sewer, Drinking Water,… B 16-4 Main oily sewer D  16-5 Main Fire Water Rings B 16-6 Main Cooling Water Supply/Return B  17 Piping (3) Piping components 17-1 Pipe/fitting/flange B 17-2 Valves B 17-3 Special Piping parts (such as strainers ) B 17-4 Sample coolers D 17-5 Extension stems D 17-6 Tubing D 17-7 Full coupling and union D 17-8 Pipe support B 17-9 Escape routes / Access Areas B 18 Others 18-1 Thermal Insulation D 18-2 Fire proof D 18-3 Acoustic insulation D References of Notes Note 1:Items shall be modeled for equipments related to process critical lines and equipments related Note 2: Thickness of fireproofing where used should be considered. Note 3: B : To be modeled in basic engineering D : To be modeled in Note 4: In principle only Note 5: If vendor information available Note 6: All technological ladder & platforms should be modeled by General note: All items has to be updated & modeled during detail Electrical, instrumentation and piping information. 1st & 2nd Review Will Be at Preliminary Phase 2nd Review contents 1st Review + U/G Review 3rd Review Will Be at Intermediate Phase

Notes for Model Review:

2nd Review

Area No. : 200 Date: 02 Nov 2011 Final Review 

 

      

  

Remark

PIP PIP PIP PIP PIP PIP

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Related to PIP PIP PIP

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PIP PIP PIP PIP PIP PIP PIP PIP PIP PIP PIP PIP

Note 1 Note 1 Note 1/4

Not Applicable Note 1/4/7/9 Note 4 Only for Pipes


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1) Model Review will be established in Mobina Building. Any probably changes in location will be informed later. 2) People from Client /Subcontractor must be present in model review meeting according to mentioned time table. 3) According to note 4.5 of model review procedure, subcontractor must have 2 sets of the following drawings in the model review room: P&IDs. Plot Plans. 4) Subcontractor must be ready for model review meeting according to attachment1 of 3D model Content for review. 5) Following people must be present as a fix people in each model review meeting: A) Person(s) from client B) Piping , process & Driver of model persons from subcontractor 6) Piping person of subcontractor must be available for every technical query related to Piping & plant design problems. 7) According to requirement of model review meeting another department people might be added to model review. 8) Subcontractors must be prepared latest 3d model with capability to Naviswork format for model review meeting.

ATTACHMENT II: COMPUTER MODEL INTERNAL REVIEW COMMENT SHEET Description:

Date:


Rev.


DOCUMENT TITLE:


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Sheet No._____ of ___ ItemNo.

Date

ITEM

Description of Comment

Action by EPY

Action by Subcontractor

Due Date

ATTACHMENT III: COMPUTER MODEL FSF REVIEW COMMENT SHEETS Description: Unit

Date:

Status


Rev.

Area No. : 200


Date: 02 Nov 2011

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Sheet No. Item No.

Date ITEM

Description of Comment

Action by EPY

Action by Subcontractor

ATTACHMENT IV – MODEL REVIEW AGENDA

Due Date

Status


Rev.


DOCUMENT TITLE:


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As required by this procedure, we will reach the preliminary phase of the model considering that equipment, structures, roads and the some of major piping circuits will be modeled. S/Contractor shall guarantee presence of key personnel for all duration of the Design Review. At least these will be: - Technical Manager or his delegate (DTM-Plant Design or SE) - Process Lead Engineer or his delegate - Piping Discipline Leader - Unit Piping PS - Driver The following is the proposed agenda for the review of the Units where enough information has been forwarded for modeling: Time table & Priority of Units and Also more details Will be Submitted later Model review based on single Units will be performed checking as minimum and where applicable, the following check list points defined on “ATTACHMENT-1-3D MODEL CONTENT FOR REVIEW” of

3D MODEL DESIGN REVIEW. ATTACHMENT V: CHECK LISTS


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The following listing assumes that the P&ID line by line check has been carried out: 1.

GENERAL LAYOUT CHECKLIST

1.1

Check that access ways and roads provide ample horizontal and vertical room for vehicles, mobile equipment etc required for efficient and safe construction, operation and maintenance of the plant.

1.2

Check location of particularly noisy equipment, valves, etc. in relation to the frequency of visits by operating and maintenance personnel to the area. Refer to Noise Report for problem areas.

1.3

Check for consistency of approach regarding access to valves, blinds, man ways, instruments, etc.

1.4

Check for economic use of scaffolding during construction phase.

1.5

Review locations of convenience outlets.

1.6

Review locations of instrument junction boxes, equipment stop/start buttons and lighting panels, and ensure they are accessible but do not restrict access to other equipment.

1.7

Review problem areas which may require additional or special lighting fittings.

1.8

For regular and safe access requirements, e.g. running adjustments, provide ladders, stairways, walkways, platforms, etc. as necessary (including manholes, relief valves, control valves, etc).

1.9

Stairway break platforms should ensure minimum distance between flights.

1.10

Avoid “dead ends” on walkways. Provide alternative escape routes.

1.11

Consider escape routes from possible danger points. All plant areas shall be designed so that operators have a minimum of two directions for escape. Plant, be it piping, instruments, equipment, supports whatever, shall not be arranged so that operators have only one escape route which may be blocked in an emergency.

1.12

Check air intakes to control room and other buildings are in safe area (using area classification standards for guidance).

1.13

Check routes for the movement of large loads within the modeled area.

1.14

Check areas for all lifting operations.


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1.15

For miscellaneous types of mechanical equipment it is not possible to be specific on the type of checks to be carried out on the model. For some equipment, e.g. blowers, some or all of the checks listed under pumps and compressors will apply. For other more specialist equipment the model should be reviewed bearing in mind the function of the equipment and considering start-up, shutdown, normal operation, maintenance, and access and safety aspects of the design.

2. 2.1

INSTRUMENTS CHECKLIST Accessibility Ensure that all instruments including remote receivers, transmitters, gauges, etc. are accessible both from an operator’s point of view and that of a maintenance engineer. Ensure instruments are not located such that they are liable to be damaged or form a tripping hazard. P&ID Checks Check that all instruments shown on the P&ID are present on the model and identified by tag number (except for temperature and pressure gauges indicated by colored tag only). Apart from identifying presence of instrumentation, the points covered by the following paragraphs should be considered. Flow Measurement Devices Check that devices are in the correct line and accessible. Devices with close coupled transmitters should be accessible from grade, platform or by ladder. If the access is by temporary ladder, check that the area beneath the device is not too congested. Review the straight runs provided for orifice plates. If flange sets are in vertical runs, check that the flow direction is correct to suit (a) liquid/steam up and (b) Gas down. Check orientation, and piping connections for flow-meters with flow direction upwards. Control Valves Check that control valves are installed in the correct line and check their location. Control valves should preferably be installed at grade with the pneumatic actuator in a vertical position. Check access for removal of large valves by lifting equipment. For angle and 3-way valves, check for correct direction of flow. Level Displacers Check the orientation of Level Displacers and Level Gauge glasses with respect to access/platforms or ladders. Where possible, access to Level Displacers should be from a platform. If an access ladder is provided, check that the instruments are visible and serviceable from the ladder. Level gauge glasses should be visible from associated level displacers and additional

2.2

2.3

2.4

2.5


2.6

2.7 2.8

2.9

3. 3.1 3.2 3.3

3.4 3.5 3.6 3.7

3.8 3.9 3.10

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space may be required if level gauges are fitted with illuminations. Check the height of platforms relative to displacer cases, bearing in mind that the instrument case associated with a rout table head displacer is approximately 30mm above the top side connection of a displacer. Temperature and Pressure Tapping. Check the location of process connections for accessibility and thermo well removal. Relief Valves Check location and accessibility for servicing. Local Panels Check positioning of local panels. Consider operational access and effect on maintenance of the plant. Analyzer House Check that measured sample line length does not result in excessive sample lag times. Check position and orientation of sample taps for a good representative sample. Check routing of fast circulating loop lines.

PIPING CHECKLIST Check location of fire-fighting hydrants, monitors and hose reels. Avoid obstructing emergency access or escape routes with piping, manifolds, valve stems, etc. Avoid trip hazards/head room restrictions from piping. Check that manual emergency shutdown valves are placed in safe visible location providing easy escape during emergency for operators. Consider remote valves as an alternative. Check that relief outlets are self-draining. Check that literal translation of P&ID has not produced excessive pipe lengths. A piping to drain is necessary for some process materials from vents and drains, as specified on P&ID. Check that permanent access to spades and ring spacers is provided where regular routine maintenance is undertaken. Where access is only required at shutdown, scaffolding can be used if there is no convenient platform. Are adequate high process point vents and low point drains provided on piping for hydro-testing and operation? Check fall on self-draining lines. Check that flanges in adjacent pipe runs are staggered to avoid flame impingement.


3.11

3.12 3.13 3.14 3.15

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Although several pipe fittings may at times be required for thermal expansion, be alert to check for cases where it may be possible to reduce what appears to be an excessive amount of pipe fittings. Optimize fittings in suction lines. Avoid burying process piping or running in trenches. Minimize use of “plastic” piping in areas where hydrocarbons may be spilt. Allow adequate clearance around small vents and drains to prevent rupture during movement of pipe work. In the critical services listed below it may be necessary to conduct a detailed hydraulic check of the model to ensure against excessive pressure drop. These checks must be made initially on layouts: Pump Suction Lines Thermosyphon Rebuilders Compressor Recycle Loops Topping Systems Inlet Lines to Safety Valves Tower Overhead Systems operating at low pressure where there may be a limited allowable overhead system pressure drop. Low Pressure Condensate Systems Other Critical systems where the allowable pressure drop may be limited

3.16

3.17 3.18

3.19 3.20

Special attention must be given to “vapors liquid” mix points in compressor systems. Piping must be arranged to avoid backflow of liquid to the compressor. A recommended procedure is to have the vapors line taken off the top of the liquid pipe. Avoid loops or pockets downstream of mix point for first 50 pipe diameters. Special attention must be given to process lines that require “no pockets” such as two phase flow, slurry, or overhead vapor lines. Check access to valves and associated blinds in accordance with frequency of operation and the project standards. Where possible make all valves and blinds accessible from grade or platforms. Check that piping does not constitute trip or head hazard nor does it block access as far as practical. A project specific checklist should be prepared for the following special areas requiring very detailed attention: Slurry lines Corrosive Fluids


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Fluids which freeze or become very viscous at ambient temperature Flammable hydrocarbons above their boiling point Fluids close to crystallization point Saturated vapors, e.g. steam, overhead systems Solids conveying systems, e.g. catalyst transfer Two phase flow, especially in vertical lines Lined Piping Lines subject to coking Reciprocating Compressor piping 3.21

Check that critical piping dimensions including minimums shown on P&IDs have been followed.

3.22 3.23

Review start-up recirculation lines to ensure valves are reasonably adjacent. Check that all atmospheric vents and manhole vents have been piped to safe location. For control valves check that P&ID notes relating to “free draining”, location, etc. have been followed. Check that vapor disengaging space (vertical section of line before any horizontal run) has been provided on column side draw offs. Check that alloy, large carbon steel, jacketed and hazardous materials pipe runs are kept to a minimum. Check hose connection locations and access, especially those handling hazardous materials. Check that hazardous material lines have minimum number of flanges. Check that blinds are on the correct side of the valve. Review steam and utilities piping, especially distribution systems from common headers with particular reference to valves of sub-headers and takeoffs to ensure an economical and practical arrangement is provided. Check location and adequacy of flushing oil, slop oil and steam-out purging connections to ensure they are minimum distance away from, e.g. Battery limit gate valve. Avoid dead legs where practical. Check whether piping can be simplified.

3.24 3.25 3.26 3.27 3.28 3.29 3.30

3.31

3.32

4. 4.1

RELIEF VALVE (RV) CHECKLIST All RV discharge lines going to flare must be self draining to the flare header which shall be indicated by an arrow. The length of the discharge line should not be excessive.


4.2

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Check all RV inlet lines for pressure drop and conformity to the “3% rule” given in API RP-520. For situations which may appear to be very tight it may be necessary to perform a detailed piping “take-off” from the model in which each length of line is measured and every fitting is accounted for.

4.3

Check that all RVs’ discharging to the atmosphere is vented at safe location. Drain (weep) holes to be provided on atmospheric discharges where liquid can accumulate. Consider piping drain to safe location.

4.4

In an all liquid system the set pressure of the safety valve is determined by its actual location relative to grade. If the valve is located close to grade, the set pressure will be higher than if it is mounted high in the air. The model should be checked for consistency between the RV location and its set pressure.

4.5

Check platform access is provided for installation, operation and maintenance of RVs. Ensure davits are provided for heavy RV’s at elevated positions. Ensure space available for drop out at grade.

5. 5.1

PACKAGED UNITS Package units shall be modeled to the same level of detail as the rest of the plant and require the same review checks. Ensure adequate space is available for installation and access and for removal of components of the package units. Ensure model reflects latest data.

6. 6.1 6.2

UTILITIES CHECKLIST Check location of utility stations relative to user points. Check location of safety showers with respect to source of hazard, access route, visibility, etc.

7. 7.1 7.2

VESSELS CHECKLIST As far as possible check for consistency with elevation shown on the P&ID. Check method of access to many ways and hand holes. Should man ways be hinged? Check direction of cover swing. Beware of adjacent instruments.

7.3

Level gauges and other instruments must be readable from either grade or platform and where indicated on P&ID readable from a drain valve or control valve bypass. Check access is provided for isolating valves. Check relative elevations of level gauge, level controller and level switch (es.). Check symmetrical piping for tower inlet and rebuilder trap out and return lines where applicable.

7.4


7.5

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For reactors and hoppers which require catalyst dumping/loading, check the elevation for suitable access and space for dumping/loading vehicle.

7.6

Check that adequate access and escape routes are provided on vessel platforms.

7.7

Check access to vessel vent, steam-out and any nozzle requiring permanent access.

7.8

Ensure adequate platform area is at location where vessel internals or packing is loaded.

7.9

Check access for trying out fractionating columns.

7.10

Check location of vent in relation to manhole to permit vessel volume to be swept out.

7.11

Ensure steam-out connection is as close as possible to tan line and at opposite end to vessel vent.

7.12

Check if the vessel can be conveniently drained. Check that outlet valves are located outside the vessel’s skirt.

7.13

Stripping steam piping to have block valve located on the horizontal and next to inlet nozzle; any small section of line between valve and nozzle must slope towards vessel. This valve must be accessible from a platform.

8. 8.1

PUMPS CHECKLIST Check accessibility to the pump for installation and maintenance. Check any special lifting tackle required.

8.2

Check inlet line configuration for double suction pumps to ensure equal distribution of flow to both suctions.

8.3 Check symmetry of piping on pumps operating in parallel. 8.4 Check adequate drains are provided on suction/discharge lines and/or pump. Pay particular attention to light ends/corrosives pumps and allow for safe removal of drained material. 8.5

Ensure no high pockets in pump suction lines (no gas locking) and top flat eccentric reducers are used at pump suctions.

8.6

Check location and orientation of swages, valves, non-return valves and fire isolation valves in suction and discharge lines.

8.7

Check symmetry of piping on pumps operating in parallel.


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8.8

Check permanent strainers are correctly located and sufficient clearance allowed for cleaning. Check that removable spools and correct support locations are provided on temporary strainers.

8.9

Check that all instrumentation associated with pumps including pump seal pots is shown and is accessible and readable.

8.10

Check cleaning, flushing, warm-up and recirculation facilities.

8.11

Check consistency of piping configuration at pumps throughout the plant.

Scope of Work for 3D-Model Procedure

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