spc-0804.02-50.91 rev d2 3d-cad model review specification

PREPARED BY NA

PTT PUBLIC COMPANY LIMITED CHECKED

BY ONSHORE COMPRESSOR STATION 4 PROJECT

APPROVED BY

CERTIFIED

(PTT) NA

REV.NO.

DATE

REVISED BY

APPROVED BY

DESCRIPTION

D1 18-Feb-08 NA ISSUED FOR ITB D2 18-Jul-08 NA REVISION ISSUED FOR ITB

SPECIFICATION FOR

3-D CAD MODEL REVIEW SPECIFICATION

SPC-0804.02-50.91 REV D1

TOTAL 22 PAGES

AREA CODE OF SITE LOCATION

GENERAL AREA: 010

.

PTT PLC. CONTRACT NO.

PTT PLC. PROJECT NO.

0804.02

3D CAD MODEL REVIEW SPECIFICATION

PTT PUBLIC COMPANY LIMITED ENGINEERING SPECIFICATION

SPC-0804.02-50.91 PAGE: 2 OF 22 REV: D2

CONTENTS

SECTION

1.0 GENERAL ........................................................................................... 3 2.0 3D-CAD MODEL.................................................................................. 3 3.0 STATUS OF ELECTRONIC MODEL......................................................... 4 4.0 ORGANIZATION OF A MODEL REVIEW.................................................. 6 5.0 ARCHIVING........................................................................................ 7 APPENDIX I : Model Review Report ................................................................. 8 APPENDIX II : Checklist for the Model Review .................................................. 9



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1.0 GENERAL 1.1 Scope This document specifies requirement and gives recommendations for 3D-CAD (Three Dimensional Computer Aided Design) visualization and use of 3D-CAD features. This document governs the procedure for conducting internal reviews (informal) and PTT (scheduled, with PTT) formal model reviews. PTT model reviews shall be conducted in the CONTRACTOR (hereinafter referred to as CONTRACTOR) offices. 1.2 Related Specification The related specifications: 1) SPC-0804.02-50.90 : 3D-CAD Modeling 2.0 3D-CAD MODEL 2.1 General The 3D-CAD model is a collection of graphical data which describes the facilities of the station for visualization purposes. The 3D-CAD model can be accessed via Review Reality (Aveva, PDMS). The graphical data is often an integral part of an engineering database supporting the design process. An important advantage of a 3D-CAD engineering database is the possibility to maintain consistency between the produced documents and to assist the co-ordination of work among different disciplines. It enables the CONTRACTOR to integrate the different design stages and the different subjects, such as piping, foundations, structures, equipment, electrics and instrumentation into one 3D-CAD model. Typical deliverables of a 3D-CAD system include:

1) Detailed engineering drawings such as plan and elevation drawings, bird’s-eye views, etc. 2) Piping Isometrics. 3) Material Take-off (Bills of Material). 4) Shaded perspective views separated in logical areas, e.g. units (model review). 5) Reports such as line lists, instrument data, interference checks (clashes).

2.2 Design Criteria Aspects The CAD system will be structured in such a way that all disciplines involved can check whether engineering criteria have been met with respect to safety, constructability, operability and maintenance. This should include accessibility for maintenance and fire fighting, location of valves, convenience of construction, process instrumentation, routing of the piping adequate for the process, location of emergency shut-down stations, proper and safe location of



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vents and drains, location of low point drain, location of fire protection and fire- fighting equipment and escape routes. 2.3 Instruction The 3D-CAD model shall be used for training and instruction of plant operators, construction staff, maintenance staff and emergency responsible organization. 2.4 Model Review Features with 3D-CAD Technology The required features shall be agreed between the PTT and the CONTRACTOR before the set-up of the 3D-CAD system and engineering database is started. Presently, the application of 3D-CAD technology allows the following: 1) Definition of classified 3D-shapes to indicate envelopes for:

- Safety. - Access / escape corridors. - Head room clearances - Valve hand wheels. - Reach / clearances for activities.

2) Access envelopes for: - Maintenance equipment. - Operability.

3) Identification of deviations from normal engineering practices. 4) Modeling of foundations and underground systems. 5) Consistency between the 3D-CAD model and the P&ID (Piping & Instrument Diagram).

2.5 Color Code for 3D-CAD Model Where practical the colors used in the 3D-CAD model shall be in accordance with 3-D Cad Modeling (SPC 0804.02-50.90) Section 4 Color Code for 3D Cad Model. 3.0 STATUS OF ELECTRONIC MODEL 3.1 General The full scope of the model is described in Engineering Standard SPC 0804.02- 50.90. The model shall meet 1/3 model review and 2/3 model review content prior to frozen. The 3D-CAD model used during the formal reviews shall be a frozen copy of the live engineering data base being used for development of the project. Any necessary changes shall be agreed upon and immediately recorded and shall be marked with tag numbers, wherever possible, to avoid misunderstanding. 3.2 Internal Reviews Internal model reviews (multi-discipline) shall be conducted regularly. All comments should be resolved prior to all PTT model reviews. Use Appendix IV “Readiness Assessment for Model Review” during the internal review.



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3.3 1/3 and 2/3 Model Reviews The models for all areas shall be reviewed jointly by the PTT and CONTRACTOR. The extent of each model review area shall be defined in a model review index for above ground areas. The model review agenda together with the model review area index shall illustrate the geographical coverage of each review. Reviews of the model should be respectively done when the model is 1/3 and 2/3 complete. But these reviews shall be scheduled so as to reflect milestone progress as conceptual and finalized detail design advances. The items listed below should have been completed for these model reviews: 3.3.1 1/3 Model Review The model minimum content for the 1/3 electronic model review shall be: (1) 8” and larger piping with in-line instruments. (2) Structures, Pipe racks (primary steel and concrete). (3) Location of access roads. (4) Location al all mechanical equipment. (5) Nozzle orientation of major equipments such inlet filter scrubber, compressor etc. (6) Packaged unit location.

(7) Escape routes defined and marked. (8) Stationary foundations.

(9) Electrical and instrument main cable route on pipe rack. (10) Building in outline, e.g. control, substation and warehouse buildings. (11) Dropout, bundle pulling and laydown areas. (12) Underground main piping lines of Oily drain, Fire water. 3.3.2 2/3 Model Review The model minimum content for the 2/3 electronic model review shall be:

(1) The actions resulting from the 1/3 model review. (2) 90% of pipelines 3” diameter and above. (3) 50% of pipelines 2” diameter. (4) Major and special pipe supports. (5) All lines defined as stress critical. (6) Packaged unit orientation. (7) Orientation of ladders, stairs, platforms on vessels and columns. (8) Utility station, Eye bath and safety shower locations. (9) Fire fighting equipment (hydrants, monitors). (10) Underground branch piping with drain funnel or connection to above

ground piping. (11) Above ground instrument and electrical tray routing. (12) Local control panels and Junction boxes. (13) Permanent cranes and hoisting beams. (14) Concrete slabs and paving. (15) All foundations and footings. (16) In-line instruments on modeled lines.



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4.0 ORGANIZATION OF A MODEL REVIEW 4.1 Participants The following discipline shall review the electronic model and related documents and shall contribute as required: (1) CONTRACTOR

- Process and Piping Engineer, Project Engineer, Review System Operator, Comments Writer: Full time - Instrument, Electrical, Static and Mechanical : Part time.

(2) PTT representatives 4.2 3D-CAD Model Review 4.2.1 Collection documents to support the review The CONTRACTOR shall give notice (approximately 2 weeks) before the review date, inform the type of review and ensure that the necessary documents to support the review are available at the time of the notice to PTT. These shall include but not limited to.

(1) Plot Plan (2) Critical Line List (3) Piping GA/Layout (4) P&ID (5) PDMS Key Plan (6) Equipment List (7) SP Item List (8) P&ID Showing status of model (9) Model Review Check List

4.2.2 Clash At least one clash run shall be carried out on the relevant files and clashes cleared before reviewing each area. 4.2.3 Review execution

(1) Check the model against the latest issue of the P&ID. (2) Follow the line-up systematically and pay strict attention to details, since many accidents are caused by seemingly minor items. Start, for instance, with the unit feed system, then proceed to internal circulation and product rundown circuits and conclude with a check on safety, fire fighting and utility systems. (3) Mark on the P&ID the lines that come under paragraph 3.3.1 & 3.3.2, equipment and instrumentation which have been checked and accepted.



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(4) Indicate the points which have not been accepted, to facilitate the review in follow-up checks. (5) Ensure that a modification is proposed whether it suits its purpose, and does not conflict with other requirements. Ensure that it is practical, safe, in accordance with the P&ID and also economic. If in doubt, consult the appropriate specialists of other disciplines. (6) Use Appendix II and III during the model review. Note that the checklist is not exhaustive and shall not overrule sound judgment.

4.2.4 Handling of Comments After each review, the team shall decide if the level of composition of the model is in line with the requirements defined in paragraph 3.4. 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. The 3D-CAD tools shall have sequence tagging facilities to describe the comments given by review team. Comment tag shall include comments line number, equipment number and sufficient detail to aid understanding. In addition, each tag must be recorded as screen snapshot. The text of each tagged shall be as complete and unambiguous as possible to avoid confusion in a later stage of the review process. The team leader shall co-ordinate the tag handling process. The tag items shall be reviewed with the PTT within 2 weeks and a record shall be produced showing which tag items will be implemented or rejected, with clearly reasoning. The relevant specialist will consult the solutions before a tag item is deleted or significantly changed. PTT comment shall not be deleted prior to formal agreement. Screen dumps of comments give rise to PROJECT SPECIFICATION changes shall be confirmed by Application of Deviation. The rolling issue of review report shall be issued on two week basis. Formal report shall be issued on monthly basis. 5.0 ARCHIVING All model and comments from Model review shall be recorded in Model Report and maintain in the Model Review Workstation through the life of project. After Mechanical completion, all models and comments from model review including comments snap shots, resolved comments snap shots shall be kept in the CD ROM and handed over to PTT.



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APPENDIX I : Model Review Report

Project No. & Name: PTT:

Review Status 1/3

Review Area (or Unit):

Page No. Review Date:

Reviewed by PTT CONTRACTOR

Tag No.

Cate- gory

Review Summary Action Taken Action by Due date

Sign

- Category Code

S : Safety, M : Maintenance, O : Operation, E : Good engineering practice,

P : Not complied with project spec. / standard



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APPENDIX II : Checklist for the Model Review

SUMMARY

Check points in this appendix 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 is comprehensive but should not be considered to be fully exhaustive.



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1.1 General Safety and Operability

No. Checkpoint Remark

1

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

2

Check that there are no obstructions in the path of escape access. Ensure the access is directed away from a process area. All staircases should route at ground level to an open area to allow an unobstructed escape access.

3

Check proper escape access from elevated equipment and all platforms. Check that at least two exits are provided on every platform which is regularly in use by operators. 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.

4

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

5

Check proper smooth connections between platforms and table tops.

6

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

7

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

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

9

Check if utility stations have been provided at the main operational platforms,



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10

Have platforms been provided at place 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).

11

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

12

Check that inlet valves of silencers on steam line 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.

13

Are hot lines or other hot surfaces near walkways properly insulated for personnel protection?

14

Check that the suction of the air blower of an analyzer container is taken from a non-hazardous area.



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1.2 Fire Prevention and Safety Equipment


1 Can firewater headers be safely accessed?

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

3 Does fire truck cover all areas while one road is blocked?

4 Can a fire truck maneuver easily?

5

Hydrocarbon process pumps should not be placed underneath pipe racks or air-cooled heat exchangers.

6 Do firewater spray systems or monitors properly protect hot pumps?

7

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

8

Check whether the layout of water spray lines and nozzles are adequate to cool vessels, if required.

9

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

10

Check if emergency showers and eye bath showers are strategically located, e.g. near equipment handling caustic, ammonia and aggressive chemicals.

11

Check the location for fire and gas detectors for their coverage.



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1.3 Piping


1

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

2

All valves, spading positions, flushing and draining and instrument connections properly located, in relation to normal operations as well as shutdown? Take special care of manifolds and large control valves.

3

If spectacle blinds are fitted, are they accessible and can they be turned safely? Consider additional or adapted platforms where applicable.

4

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

5

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

6

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

7

Do vapor lines, including steam lines, freely branch off from the top of main lines?

8

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.

9

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

10

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



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11

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

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

13

Do compressor suction lines slope towards the knockout drum? Each low point of the compressor suction should have a low point drain.

14

Check the position of eccentric reducers. Normally the straight part is on the bottom of horizontal lines, except in pump suction lines where vapor pockets may cause cavitations of the pump.

15

Check that small bore cooling water lines branch off from the top of header.

16

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

17

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

18

Is piping with instrument connections positioned such that these connections are easily accessible? Is the measurement point in the correct process location?

19

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

20

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 lines?

21

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



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1.4 Valves


1

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

2

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

3.

Check that there are no valves installed with the stem pointing downward, except flare lines.

4

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

5 Are valves operable from grade level or floor?

6 Are valves that need frequent attention easily accessible?

7

Check for valves in vertical lines which may accumulate liquid (e.g. condensate).



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1.5 Pumps and Compressors


1

Is valve around pumps and compressors accessible and operable?

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.

3 Is removal of the pump and the electric motor practical?

4

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

5 Have high points in pump suction lines been avoided?

6

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

7 Is location of the local compressor panel logical?

8 Is there space for crane to enter and maneuver?

9

With regards to swing check valve in pump discharge side, is it considered avoiding slamming motion of valve disc due to its gravitational weight? Comparatively large size swing check valve shall be recommended to install in horizontal side to avoid slamming.

10

Checked whether the permanent strainer can be easily removed when required for maintenance.



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1.6 Vessels and Columns


1

Check that manholes are within reach of hoisting equipment?

2

Ensure proper space on platforms for turning the manhole covers and for entering equipment.

3

Are instrument tapings and local instruments and level glasses readily accessible?

4 Has insulation for personnel protection been provided?

5

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

6 Check free movement of platforms (thermal expansion).

7

Check if specified elevations of vessels and columns on P&ID are adhered to.

8

When differential expansion between column and connected piping on it is big, is the piping support proper installed to accommodate thermal expansion?



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1.7 Relief systems: Flares and Vent Systems


1

Flare lines shall have no pockets and shall slope continuously to the flare knockout drum. If a low point is unavoidable, ensure a drain with adequate size is connected to a drain

2

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

3

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

4 Check that outlet lines from relief valves are self-draining into the flare header.

5 Check that connections are made on top or on the side of the flare header.

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.

7 Is safety/relief valve piping as possible when discharging into a close system?

8

Check relief valves discharging to atmosphere for safe locations 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,

i l i hi h k

9 Can relief valves be blocked-in and drained?

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

11 Is reactor vent gas safely routed during regeneration?

12 Ensure that flame arrestors in lines to the atmosphere can be accessed for removal and maintenance.



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13

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



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1.8 Environmental Check


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.

2 Check drainage from pump casings and pump strainers.

3 Check drainage from process filters and coalescers.

4 Check drainage from fuel filters of furnaces.

5

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

6

Check drainage from heat exchangers when opened for bundle cleaning or repairs.

7

Consider also the effect of liquid spillage when opening both heads as well as when pulling the bundle. Check drainage of sour or spent seal and tube oils from compressors.

8

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

9

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

10

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

11

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



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APPENDIX III: Readiness Assessment

For 1/3 Model Review Project No. & Name: Review Area (or Unit): ______________________

Activity

Pipi

ng

Proc

ess

Civ

il/Str

uctu

re

Mec

hani

cal

Elec

tric

al

Inst

rum

ent

Comments

1 Location of all mechanical equipment. O O

2 Construction and maintenance aspects verified. O O

3 Dropout, bundle pulling and laydown areas. O O

4 Check escapes routes. O

5 Pipe racks and structures shown. O

6

Building in outline: - Control room - Analyzer shelters - Switch rooms

O O O

7 Location of access roads shown. O

8 Stationary foundations shown. O

9 Packaged unit located. O

10 Nozzle orientation of major equipments such as towers, columns, reactors.

O

11 All large bore piping 6” and above with in- line instruments on modeled lines.

O

12 Electrical and instrument main cable route on pipe racks. O O

Approved by Piping L/E _________________ Approved by Project _________________ Signature _________________ Signature _________________ Date _________________ Date _________________



SPC-0804.02-50.91 PAGE: 22 OF 22 REV: D2

For 2/3 Model Review Project & Name: Review Area (or Unit) _______________

Activity

Pipi

ng

Proc

ess

Civ

il/Str

uctu

re M

echa

nica

l

Elec

tric

al

Inst

rum

ent

Comments

1 Comments from 1/3 model review incorporated and approved byPTT. O O O O

2 Operation and maintenance aspects verified. O O O

3 Dropout, bundle pulling and laydown areas. O O

4 Final dimensions of structures and steel constructions. O

5 Permanent cranes and hoisting beams. O

6 All foundations and footings shown. O

7 Orientation of equipment nozzles. O

8 Packaged unit orientation. O

9 Orientation of ladders, stairs, stairs, platforms on vessels and columns. O

10 Utility station, Eye bath and safety shower locations. O O

11 90% of pipelines 3” diameter and above, 50% of pipelines 2”diameter O

12 Major and special pipe supports. O O

13 Stress comments incorporate for defined as stress critical. O

14 Fire fighting equipment (hydrants, monitors, water spray systems, etc) located.

O

15 All underground piping. O

16 Underground sewer systems and collecting and separation systems. O O

17 Concrete slabs and paving O

18 Above ground instrument and electrical tray routing. O O

19 In-line instruments on modeled lines. O O

20 Local panels and junction boxes. O

21 Clash checks complete. O O O O

Approved by Piping L/E ______________ Approved by Project ____________ Signature _________________ Signature _________________ Date _________________ Date _________________

spc-0804.02-50.91 rev d2 3d-cad model review specification

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