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Table of Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Introduction References General Piping Design Piping Engineering Vessel Engineering Civil, Architectural and Structural Engineering Electrical Engineering Specific Control Systems Aspects. Mechanical Engineering Mechanical Engineering General Equipment. Mechanical Engineering Fired Equipment Mechanical Engineering Fire-Fighting.
1. Introduction
The purpose of this checklist is to provide guidelines to the Group Manager, and/or the design review team in conducting a design review.
2. References
Document Number Title Level
2.1
CM-PE-306
2.2
BN-S-UK003
Checked by the relevant departments/groups for inclusion of: Safety valves Metallurgy Pressure/temperature design conditions Alternative process conditions Philosophy of alarming and shutdown Sparing philosophy
y y y y y y
3.5 Drawings
y y
All Company design drawings to be checked. Vendor drawings to be checked in sufficient detail to assure that care has been taken that all important details comply with good engineering practice and governing code rules. Vendor calculations to be checked if safety of design is involved.
y y y y y y y y y y y y y
Availability of utilities and effects of their failure Explosion risk under maloperation Safety valves releasing to atmosphere well away from platforms Vents and drains safely located Radiation due to burning vapor releases Radiation from vapor releases Radiation from hot surfaces Shrouding and covering of terminals Sealing of dangerous substances, and disposal of such substances if used Leakage rate Release of toxic gases and substances Gas detection systems inclusive alarming Flame failure in fired heaters
3.7 Climate
y y y y y y y y
Rainfall intensity, frequency and duration Snow, effect of dust, sand, etc. Wind velocity and direction Seismic effects Temperature effects, frost depth and durability of materials Humidity Effect of sun radiation Thermal expansion of liquids
4.2 Design
y y y
Group Manager/Squad Leader and Project Engineer shall assure that the Process Department has identified and listed all equipment and lines in lethal or toxic service or requiring special attention for safety reasons, and that such equipment and lines are clearly marked in the equipment list and line table. Group Manager/Squad Leader shall check that the Process Department has identified and listed all equipment and lines involved in extreme design conditions, that such equipment and lines are clearly marked in the equipment list and the line table, and that any effect on piping design has been reviewed. The requirements for authority approval for lines and/or equipment shall be established and approved in conjunction with Client and/or Project Manager. Lines subject to authority approval shall be marked as such in the line table and on the isometric drawings.
y y
The Squad Leader shall check that all lines and connections to equipment have been reviewed to ensure compliance with stress and all equipment requirements. Supports, stops, guides, expansion joints, loops, anchors, sway arrestors and slide plates shall be installed as required to affect this, and lines shall be reviewed for adequate supporting. Particular attention shall be given to strain sensitive equipment, such as pumps and compressors.
5.2 Engineering
y y y y y y y y y y y y y
Group Manager/Lead Engineer shall assure that the Process Department has identified and listed lines in lethal or toxic service or requiring special attention for safety reasons. Group Manager/Lead Engineer shall assure that the Process Department has identified and listed all lines involved in extreme design conditions. The requirements for authority approval for lines shall be established and approved in conjunction with Client and/or Project Manager. The Piping Engineer shall assure that all lines and connections to equipment have been reviewed for compliance with stress and all equipment requirements. Supports, stops, guides, expansion joints, loops, anchors, sway arrestors and slide plates shall be installed as required. Review for adequate supporting and check supports drawings carefully. Particular attention to be given to strain sensitive equipment such as pumps and compressors. Component type selection criteria shall be laid down and incorporated in component requisitions. Requirements for supplier's certificates to be defined and it shall be assured that such certificates are adequately verified. Testing methods and conditions shall be evaluated. Calculations for stress, flexibility, etc. shall be checked and signed by the Lead Engineer and approved and signed by the Group Manager. Check that suitable (inter)locking has been called for at multiple relief valve assemblies, and all other locations where mechanical locking is required according to P&I diagrams. The effect of various operating modes shall be reviewed. The presence of sufficient expansion loops shall be checked. Water hammer and similar types of studies shall be made and reviewed. Erosion and corrosion aspects shall be studied.
6.2 Engineering
y y y y y y y y y y y
Group Manager/Lead Engineer shall assure that the Process Department has identified and listed all equipment: In lethal or toxic service Subject to authority approval Requiring special attention for safety reasons. Group Manager/Lead Engineer shall assure that the Process Department has identified and listed all equipment involved in extreme design conditions. The requirements for authority approval for equipment shall be established and approved in conjunction with Client and/or Project Manager. Calculations for wall thicknesses, stresses, etc, to be checked and approved by the Lead Engineer. Requirements for supplier's certificates shall be defined and it shall be assured that such certificates are adequately verified, including material identification. Erosion and corrosion aspects to be studied. Testing methods and conditions shall be evaluated. The effect of various operating modes to be reviewed.
7.2 Environmental
y y y y y
Marine and industrial environments, additional protection to structures. Ground water movements, requirements for subsoil drainage. Prevention of chemical attack by soils or ground water. Site checked on possibly existing soil/ground water pollution (in view of reuse of soil and attack of foundation and underground facilities). Paving and surfacings designed to prevent seepage of product spillages/leakages into the subsoil/ground water.
y y y
Vital functions protected by blast-resistant construction: control rooms, computer rooms and other buildings as necessary, including penthouses Pressurization Clean and sterile conditions
7.6 Drainage
y y y y y y y y y
Separate systems for noxious fluids Adequate drainage for fire water Adequate drainage for safety showers and eye baths Bunding of storage tank areas Safety locations for settlement tanks and waste sumps Provision of drainage for bunded areas Provision of drainage for cable trenches Provision of effluent treatments for release into natural environmental or recycling for reuse Provision of adequate fire seals at least at the exit from each area of all services
8.2 Earthing
y y y y y
Protection against lightning Discharge of static electricity Dispersal of fault currents Limiting step and touch potentials to safe levels Protection of earthing conductors against corrosion
8.5 Cabling
y y y
Compliance with regulations Correct conductor sizing Adequate protection for cables
8.7 Equipment
y y y y y
Ease of maintenance Accessibility Equipment for Uninterruptable Power Supply System (UPSS) Required certificates, available and verified Selection of alternate Power Supply (Turbine/Diesel)
9.2 Earthing
y y
Limiting touch potential to safe levels Protection of earthing conductors against corrosion
y y y y y
Shutdown systems/emergency depressurizing system Fail-safe features affecting plant safety Effect of failure or loss of electricity, or any other utility Burner management systems Excess flow valves or restriction orifices
9.7 Cabling
y y y y
Compliance with regulations Correct conductor sizing Adequate protection for cables Segregations
9.12 Miscellaneous
y y y y y
HVAC for control systems equipment Availability of purge and drainage systems Equipment in lethal or toxic service Material certification Authority approvals and permits
10. Mechanical Engineering 10.1 Data Sheets to be completed with following information where applicable:
y y y y y y y y y y
Properties of materials processed Nozzle loadings Pressure/temperature rating Mechanical seal design and circulating system Metallurgy Toxicity of fluids Protection equipment - gauges, switches, relief valves, trip devices and guards Electrical classification Cooling and lubrication systems Acoustic insulation
10.2 Documentation
y y y y y y y
Noise specifications/arrangement drawings/installation and operating manuals Check that: Equipment complies with noise requirements Safe layout and accessibility is available Vendor manuals cover safe installation and operation Welding procedures are acceptable Check that proper certificates have been supplied and that these have been verified
10.3 Miscellaneous
y y
Presence of dead legs or spaces Maintenance requirements satisfied
11. Mechanical Engineering General Equipment 11.1 Data Sheets to be completed with relevant information such as:
y y y y y y y y y y
Properties of materials processed Nozzle loadings, if applicable Pressure/temperature rating Metallurgy Noise data Insulation Tracing Protective Equipment Electrical area classification Provision of effluent treatment for release into natural environment or recycling for reuse
11.2 Documentation
y y y y y y y y
Noise specifications/arrangement drawings/installation and operating manuals Check that: Equipment complies with noise requirements Safe layout and accessibility is available Vendor manuals cover safe installation and operation Welding procedures are acceptable NDT records have been completed Check that proper certificates have been supplied and that these have been verified
y y y y y y y
12.2 Documentation
y
Vendor to supply requested documents such as: general arrangements and detail drawings/refractory data/installation and operation manuals. Start-up and Shut-down temperature curve. Check that:
y y y y y
Equipment complies with noise regulations Safe layout and accessibility is available Vendor manuals cover safe installation and operation Proper certificates have been supplied and that these have been verified by the Inspection Group All other documentation has been supplied
12.3 Burners, Furnace Radiant Cells and Other Fire Boxes 12.3.1 Burners
y y y y
Selection of type and location Protection against inadvertent admittance of fuel Flame out control device Burner management system
12.4.2 Dampers
y
Damper operation
12.4.3 Stacks
y
Free standing or guyed - aircraft warning lights - access
Environmental requirements
y y y y y
y y y y
Seismic probability and effects Adequate fire exits and escape routes Dynamic effects Permanent lifting equipment
12.7 Electrical
Reference is made to procedure DE-SP-350: Safety Procedure: Guidelines for Safety Reviews of Electrical. Specific attention is required for: Hazardous area classification Adequate illumination Emergency lighting
y y y
y y y y y
Specific attention is required for Design conditions of coils in view of blocked operation
Fire-Fighting
Fixed foam systems (sub-surface or semi-sub-surface) for fixed roof tanks BCF systems (with dry riser backup) for floating roof tanks Halon 1301 flooding fire suppression systems in building High expansion foam generators Hose reels, hose boxes, fire points Fire extinguishers Fire blankets