BN-S-UK004 Checklist Design Review Technical Disciplines

Table of Contents

1. Introduction
2. References
3. General
4. Piping Design
5. Piping Engineering
6. Vessel Engineering
7. Civil, Architectural and Structural Engineering
8. Electrical Engineering
9. Specific Control Systems Aspects.
10. Mechanical Engineering
11. Mechanical Engineering General Equipment.
12. Mechanical Engineering Fired Equipment
13. 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

3. General

3.1 Regulations

• Requirements of the law
• Regulations (national and local)
• Client's requirements
• Codes of practice (international/national)
• Company standards

3.2 Job Instructions

• Project Specification
• Project coordination procedure
• Project instructions
• Job specifications approved by the Project Manager
• Degree of inspection required

3.3 Basic Documents

• Process data sheets
• P & I diagrams
• Logic diagrams
• Hazardous area classification
• Pressure/Temperature profile
• Piping specification
• Plotplans
• Equipment list
• Line tables

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

3.4 Material Selection

• Material selection effected in conjunction with Welding, Metallurgical and Process Engineers where relevant. Reactivity, corrosivity, toxicity and erosion properties of substances processed taken into account.

3.5 Drawings

• 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.

3.6 Safety to Personnel and Environment

• Alarm systems
• Protection against electric shock and earthing metallic parts
• Protection against excessive noise
• Overspeeding protection
• Electrical clearances
• Screening of live parts, including hot surfaces
• Guarding of moving parts
• Flammability and toxicity of substances
• Drain locations and destinations
• Short circuit and earth leakage protection
• Correct thermal and sound insulation levels
• Process flow failure
• 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

• 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

3.8 As-Built Plant

• Effects of erroneous or improper operation of equipment
• Suitability for turnaround operations
• Maintenance aspects
• Checking and testing possibilities of piping systems and fixed equipment, including control systems

4. Piping Design

4.1 Piping Specification

• Group Manager/Squad Leader shall check that relevant engineer­ing guides for completion of Piping specification have been followed.

4.2 Design

• 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.
• 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.

4.3 Plant Layout and Equipment Location

• Check area classification drawing for pits and other catchment devices.
• Check flare radiation zone is outside walk ways and access areas.
• Check that there is a minimum of 15 m clearance from fired equipment to hydrocarbon bearing equipment.
• Check sprinkler system layout for pumps and compressors.
• Check suitability of fire fighting equipment, location of hydrants and adequacy of water supply.
• Check to ensure that adequate access for fire tender has been provided to all relevant plant locations.
• Check lifting facilities and crane access for maintenance, together with drop-out areas.
• Check that clear escape routes have been provided.
• Check that ladders and stairs are positioned at grade leading to clear escape routes.
• Stairways must be the primary access to main operating or service platforms.
• Ensure that no zinc/galvanized items are installed above austenitic Stainless Steel Pipes and/or Equipment.
• Auxiliary exits by ladders to be provided.
• Check safety closures between platforms and ladders.
• Check that ladders are caged where necessary, and that no ladders are longer than 9 m in one run.
• Check for sufficient railing.
• Check toe-plates along railing and floor-holes.
• No dead end platform to be longer than 8 m.
• Horizontal unobstructed walking distance to primary or auxilia­ry exits shall not exceed 15 m.
• Check that fire decks are present below e.g. air fin coolers.
• Check to ensure that adequate walkways have been provided to operate and maintain the plant.
• Check minimum space and headroom clearance.
• Check on flame arrestor requirements for vent pipes.
• Check on vent requirements for underground drainage systems.
• Check for seals in process drains connected to sewers.
• Check that all vent pipes and relief valve manifolds discharg­ing to atmosphere are at least 3 m above any platform within a radius of 15 m.
• Check that suitable interlocking has been called for at multi­ple relief valve assemblies.
• Design Engineering Supervisor in conjunction with Process and Project shall check suitability of all relief system arrange­ments. Particular attention shall be given to the possibility of pockets/vapor locks and discharge requirements and use of and/or need for closed systems.
• Check suitability of safety shower and eye bath locations. Ensure that water supply cannot freeze, adequate drainage has been provided and that overheating cannot occur.
• Check locations of gas detection systems if provided on the plant.
• Check that the control room is at a safe location.
• Check that all rotating and moving parts machinery are ade­quately guarded.
• Check that all drains from lines containing hazardous fluids are run to grade at safe location, and all vent outlets from these lines are at safe location.
• Assure that no drain funnels are located in runways.
• Check that open and closed drains are not combined.
• Check insulation flanges in cathodic protection systems.

5. Piping Engineering

5.1 Piping Specification

• Relevant engineering guides for completion of Piping specifica­tion shall be followed as applicable.

5.2 Engineering

• 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. Vessel Engineering

6.1 Vessel Specification

• Vessel Specification(s) to be completed with notes regarding safety items, quality control and inspection to be considered by vendors.

6.2 Engineering

• 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. Civil, Architectural and Structural Engineering

7.1 Geophysical

• Ground bearing capacity
• General settlements of foundations
• Differential settlement of foundations
• Seismic probability and effects
• Altitude

7.2 Environmental

• 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.

7.3 Fire Risks

• Fire resistance of structural elements
• Provision of fire precautions, such as fire proofing (excluding deluge, sprinkler systems, fire mains and other fire fighting means). Reference is made to procedure DE-SP-373: Safety Procedure: Guidelines for Safety Reviews of Mechanical Engineering: Fire Fighting
• Adequate fire exits and escape routes
• Possible spreading of fires via open trenches/ditches
• Ensure that no zinc/galvanized items are installed above austenitic stainless steel pipes and/or equipment
• Fire walls and required fire resistance periods for enclosures

7.4 Safety to Personnel

• Provision of guard railing at elevated work locations
• Provision of safety railing for accessible dangerous areas,i.e. roofs, pits, etc.
• Provision of safety cages on ladders
• Fitting of snow guards to pitched roofs
• Demarcation of non-bearing roof areas
• Slip-resistant floor surfaces
• Elimination of trip hazards
• Adequate access plus suitable road specification, gradients and radii for fire fighting vehicles and ambulances
• Adequate spaces allowed for operations and clearances around equipment

7.5 Explosion and Fire

• All potentially explosive areas contained by blast relieving construction
• Provision of fire walls
• 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

• 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. Electrical Engineering

8.1 Hazardous Areas

• Identification of source of hazards
• Identification of substances released
• Establishment of risk zones
• Establishment of temperature class and gas groups
• Selection of certified equipment

8.2 Earthing

• 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

8.3 Cathodic Protection

• Protection of buried metals
• Interference with earthing system

8.4 Area & Road Lighting

• Adequate illumination
• Lights correctly positioned
• Avoidance of too much glare or reflection
• Adequate emergency lighting

8.5 Cabling

• Compliance with regulations
• Correct conductor sizing
• Adequate protection for cables

8.6 Electrical Protective Equipment

• Correct type and sizing of fuses
• Selection of relays
• Relay coordination

8.7 Equipment

• Ease of maintenance
• Accessibility
• Equipment for Uninterruptable Power Supply System (UPSS)
• Required certificates, available and verified
• Selection of alternate Power Supply (Turbine/Diesel)
  

9. Specific Control Systems Aspects

9.1 Hazardous Areas

• Design philosophy
• Selection of certified equipment, and verification of certifi­cates received
• Compliance with area classification drawing
• Installation to code and specific certificate requirements
• Location of control, satellite rooms/houses and analyzer buildings

9.2 Earthing

• Limiting touch potential to safe levels
• Protection of earthing conductors against corrosion

9.3 Fire Protection

• Smoke/fire detection (control systems equipment)
• Shutdown, interlock and alarms
• Fire resistance of materials
• Operational implications of a fire
• Fire fighting system (control systems equipment)
• High fire risk areas, application of fire proofing

9.4 Fail-Safe Design

• 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

9.5 Safety Relieving Devices

• Sizing criteria
• Capacity correction for back-pressure
• Approval of calculations and selection of type
• Special relieving systems, such as combinations of relief valve with rupture disc
• Location

9.6 Equipment Location and Connections

• Maintenance
• Accessibility
• Mechanical strength of connections
• Limitation of number of connections

9.7 Cabling

• Compliance with regulations
• Correct conductor sizing
• Adequate protection for cables
• Segregations

9.8 Electrical Supply System

• Correct type and sizing of fuses and circuit breakers
• Extent of equipment of Uninterruptable Power Supply System (UPSS)
• Alarms
• Overall power consumption

9.9 Air Supply

• Instrument air consumption
• Security of supply
• Operational and design conditions

9.10 Process Control

• Analyzer philosophy
• Process computer and its software
• Cyclic operation

9.11 Plant Surveillance and Monitoring

• Vibration monitoring
• Plant monitoring by operators, closed TV-circuit, etc.
• Detection of unusual process conditions

9.12 Miscellaneous

• 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:

• 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

• 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

• 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:

• 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

• 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

12. Mechanical Engineering Fired Equipment

12.1 Data Sheets

Data Sheets to be completed with following information where appli­cable:

• Properties of materials processed
• Pressure/Temperature rating (operating as well as mechanical design)
• Metallurgy
• Electrical area classification
• Acoustic and thermal insulation equipments
• Specification/data sheets of auxiliary equipment
• References to applicable standards/specifications

12.2 Documentation

• 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:
• 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

• Selection of type and location
• Protection against inadvertent admittance of fuel
• Flame out control device
• Burner management system

12.3.2 Furnace Radiant Cells

• Presence of peep holes and other inspection facilities
• Heat insulation lining, including anchoring
• Casing temperatures

12.3.3 Other Fire Boxes (including flare tips)

• Material selection
• Heat insulation lining, inclusive anchoring
• Electrical area classification
• Acoustic and thermal insulation equipments
• Specification/data sheets of auxiliary equipment
• References to applicable standards/specifications

12.4 Ducts, Dampers and Stacks

12.4.1 Ducts

• Heat insulation lining including anchoring
• Thermal expansion provisions
• Operability of blind plates including guillotine blinds

12.4.2 Dampers

• Damper operation

12.4.3 Stacks

• Free standing or guyed - aircraft warning lights - access
• Environmental requirements

12.5 Layout and Piping Design

Reference is made to procedure DE-SP-310, Safety Procedure: Guide­lines for Safety Reviews of Piping Design. Specific attention of the piping group is required for:

• Clearance to hydrocarbon bearing equipment
• Escape routes
• Adequate walkways
• Access for mobile lifting equipment
• Drop-out areas for permanent lifting equipment

12.6 Foundations and Structural Steel

Reference is made to procedure DE-SP-340: Safety Procedure: Guide­lines for Safety Reviews of Civil/Architectural and Structural.

Specific attention is required for:

• 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

12.8 Control Systems

Reference is made to procedure DE-SP-360: Safety Procedure: Guide­lines for Safety Reviews of Control Systems.

Specific attention is required for:

• Hazardous area classification
• Specification and location of analyzers for oxygen content, etc.
• Number and location of pressure and temperature measurement connections
• Safety valves on steam coils
• Burner management system

12.9 Pressure Vessels

Reference is made to procedure DE-SP-330: Safety Procedure: Guide­lines for Safety Reviews of Pressure Vessels.

Specific attention is required for

• Design conditions of coils in view of blocked operation

13. Mechanical Engineering ─ Fire-Fighting

13.1 Fire Fighting Methods

• Hydrants
• Monitors
• Automatic spray/fog systems
• 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

13.2 Fire Alarm Systems

• Fire alarm call points
• Fire alarm bells/sirens.

13.3 Fire Fighting Availability

• Availability of fire water
• Availability of fire water pump(s)
• Tracing of fire water supplies, including dead ends of continu­ously filled systems
• Fire station
• Fire fighting trucks and vehicles.