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DEP 30.10.05.11-Gen.
February 2012
DEP 30.10.05.11-Gen.
February 2012
Page 2
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1)
Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2)
Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3)
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after
use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
DEP 30.10.05.11-Gen.
February 2012
Page 3
TABLE OF CONTENTS
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
INTRODUCTION ........................................................................................................4
SCOPE........................................................................................................................4
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........4
DEFINITIONS .............................................................................................................4
CROSS-REFERENCES .............................................................................................5
SUMMARY OF MAIN CHANGES...............................................................................5
COMMENTS ON THIS DEP .......................................................................................5
DUAL UNITS...............................................................................................................6
2.
GENERAL...................................................................................................................7
3
3.1
3.2
3.3
3.4.
4.
4.1
4.2
4.3
4.4
4.5
4.6
5.
5.1
5.2
5.3
5.4
5.5
6.
6.1
6.2.
6.3
6.4
6.5
6.6
6.7
7.
ARCHIVING ..............................................................................................................28
8.
REFERENCES .........................................................................................................29
APPENDICES
APPENDIX I
APPENDIX II
DEP 30.10.05.11-Gen.
February 2012
Page 4
1.
INTRODUCTION
1.1
SCOPE
This DEP specifies requirements and gives recommendations related to the BDEP (Define)
and Execute (detailed engineering) phase of projects for:
3D-CAD models.
Level of detail for the Define Phase is described in (4), 3D-CAD Model. The quality of the
model content shall be communicated to the Principal (i.e. content model based on
preliminary information, piping based on dummy/standard specifications, etc.).
Visualisation tools other than 3D-CAD tools (e.g. virtual reality) are not covered by this
DEP. The use of such tools is subject to the agreement of the Principal.
This is a revision of the DEP of the same number dated January 2005; a summary of the
main changes is given in (1.5).
1.2
1.3
DEFINITIONS
1.3.1
General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
DEP 30.10.05.11-Gen.
February 2012
Page 5
1.3.2
1.4
Abbreviations
Term
Definition
3D-CAD
BDEP
CAD
HFE
HSE
HVAC
PFS
PEFS
TA
Technical Authority
VCA
CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets ( ). Other documents referenced by this DEP are listed in (8).
1.5
1.6
DEP 30.10.05.11-Gen.
February 2012
Page 6
1.7
DUAL UNITS
This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
DEP 30.10.05.11-Gen.
February 2012
Page 7
2.
GENERAL
In the course of the Define stage of a project, the construction of a 3D-CAD block model
may be useful depending on the type, size and complexity of the plant.
In the early phase of a project, the 3D modelling tool may be used for locating the buildings,
main equipment and the main pipe routings.
As part of BDEP (Define) Phase, a 3D-CAD block model should be constructed.
As part of the Execute Phase (detail engineering) a 3D-CAD model shall be constructed.
A 3D-CAD system is a design tool for the Contractor and an integral part of the design and
engineering process. The visualisation used for the 3D-CAD "model review" is only one of
the features of a 3D-CAD system.
The 3D-CAD model reviews are performed by the Contractor at 3 stages during the design.
The 3D-CAD system also provides a clash free design for all engineering disciplines
involved, all the construction drawings and can assist in controlling the construction
materials (through listings per unit, rack or class).
The model provides a visual check on safety, operability, accessibility, maintainability and
facilitates the engineering and erection of the units (erection path can be implemented in
the model). It may also be used for the training of operators (including safety training) and
for the planning of efficient maintenance schedules, to assist construction work (e.g.
handling of heavy or large equipment) and commissioning planning.
DEP 30.10.05.11-Gen.
February 2012
Page 8
3
MODEL REVIEWS
3.1
GENERAL
The Contractor shall perform formal 30 %, 60 % and 90 % model reviews to check that the
arrangements meet the Principal's requirements.
The purpose of a 30 % model review in the Execute Phase, is to freeze the basic plot
layout and to reach agreement on the proposed design to enable the Contractor to proceed
into detail design. Where plot layout is critical, and as such affects feasibility, it is required
to be executed as part of the BDEP (Define) Phase of the project.
The purpose of the 60 % model review in the Execute Phase, is to confirm the design is
in-line with the PEFS, Supplier data and all other design relevant documentation. After the
review the Contractor should be able to finalise the deliverables for construction.
The purpose of the 90 % model review in the Execute Phase, is to confirm on the
comments from the 60 % and to finalise on the total design of the model.
These reviews should be undertaken in detail, checking each unit for safety routes,
operability, maintainability, accessibility and constructability and checking each system in
the unit using the PEFS to make item-by-item checks.
The modifications initiated during previous model reviews shall be implemented before the
next official model review.
The Contractor shall perform in-house model checks prior to the formal model reviews. The
results of these in-house reviews shall be documented. Any changes which impact the
results from prior reviews shall be brought forward to the Principal at start of the formal
review.
All items as listed for the relevant 30 %, 60 % and 90 % model reviews shall be part of the
3D model. Any deviation from the lists shall be reported by the Contractor to the Principal,
well in advance of the formal 3D model review.
Any necessary changes shall be agreed upon and immediately recorded and shall be
marked with reference numbers and model pictures to allow proper follow up and to avoid
misunderstanding.
From each formal 3D-CAD model review, an electronic copy of the presented model shall
be saved by the Contractor and handed over to the Principal (if required).
When the Contractor, during the BDEP (Define) Phase, constructs a 3D-CAD block model,
model reviews have to be held to check that the arrangements meet the Principals
requirements. See (5): BDEP Define phase.
3.2
TOOLS
A 3D-CAD model presentation for a group of people should be performed using a large
screen having a high resolution. Point-to-point distance measurements shall be possible on
request, to be able to verify compliance to clearance and access requirements or approve
slight deviations. Main computer manipulations, such as switching to another process unit
should not take more than 2 minutes. Reference items, mobile cranes, bundle pulling
equipment, etc. and an operator of the same scale as the model under review, shall be
available. The model operator's dimensions shall be conform to the the workspace design
requirements of DEP 30.00.60.20-Gen. Deviations or "cultural calibration" can be done on
regional level and approved by the appropriate HFE TA.
It should be possible to save snapshots and to indicate on the overall picture (e.g. projected
in the corner of the screen) where the review detail is located.
The full model presentation should be given in a darkened room with sufficient dimmed light
to enable drawings to be read and notes to be made without interfering with the
presentation. The review must be held in a room that is fit for purpose (enough space and
good view on the 3D model). A sufficient number of pointers should be available to point to
items shown on the screen and to improve the efficiency of discussions.
DEP 30.10.05.11-Gen.
February 2012
Page 9
The following information shall be available in clear legible prints for all participants:
a) Process Flow Schemes (30 %);
b) Process Engineering Flow Schemes (60 %, 30 % as far as available);
c) Plot Plan;
d) Equipment arrangements;
e) Line List + Critical Line List (through computer access to project documentation
system during review);
f) Individual equipment information, data sheets (on request);
g) Civil structural drawings (on request);
h) Stress calculations (on request);
i) Piping studies (through computer access to a dedicated electronic folder during
review);
j) Material (equipment) handling studies;
k) Fire safety studies;
l) HSE reviews;
m) Listing of agreed standards;
n) Level of completeness of model (Clash report) and quality of catalogues.
3.3
TEAM COMPOSITION
A team leader from the Contractor shall be appointed who is fully familiar with the project,
the model and the 3D-CAD system capabilities. The team leader shall guide the team
through the model with the assistance of the system operator. The team leader shall be
responsible for the efficiency of the review process, the adequate reporting of comments
made and the subsequent follow-up.
The efficiency of the model review largely depends on the experience and knowledge of the
system operator and secretary. Both the system operator and secretary shall be fluent in the
project language, and should understand the technical terms used within the industry. The
system operator should be heavily involved in the design of (the area of) the model under
review. He is familiar with the technical content of the model and can clarify the design to
the team members when necessary. A secretary shall be available to take meeting notes,
and throughout the full review, take down any comments without discussion,
To prevent specialist sub-meetings during a model review, which distract the attention of
other team members, teams should not be larger than 10 members excluding the
contractor specialists. If a larger number of people is necessary for a model review
separate teams should be formed of members with a common interest in the subject(s)
under review. Each team shall than review the model independently, and at the end of the
review the team leader shall plenary discuss any conflicting recommendations made by
each individual team.
The composition of the review team depends on the progress of the model.
3.4.
HANDLING OF COMMENTS
The 3D Model Review Minutes shall encompass all the comments made in the session,
state the actions to be taken, the responsibilities and time frame of implementation
After every review (30 %, 60 %, 90 %), the Principal team shall decide if the level of
completion of the model is in line with the requirements defined in (6.2) and (6.3).
Shortcomings in the degree of completion shall be highlighted and, after correction,
checked in the next review, or in an additional review depending on the degree of
incompleteness and the project schedule.
DEP 30.10.05.11-Gen.
February 2012
Page 10
Comments on the model shall be electronically tagged during the review. The 3D-CAD tools
should have sequence reference facilities to describe the comments given by the review
team. The text of each reference shall be complete and unambiguous and include a
snapshot to avoid confusion in a later stage of the review process. Electronic tag files shall
be archived as a permanent record of review comments. A Log List shall be applied for the
Review Sessions in order to keep record for all comments.
The team leader shall co-ordinate the tag handling process. The tagged items shall be
reviewed by the Contractor within 2 weeks and a record shall be produced showing which
tag items will be implemented or rejected, with reasoning. The relevant specialist or
technical authority as appropriate shall be consulted, and the other team members shall be
informed, before a tag item is deleted or significantly changed.
The Contractor may proceed when deviations or non compliances are agreed and
approved by the appropriate TA present in the 3D model review. However audit trail for
deviation/ derogation register shall be followed up by the Shell project team.
Before the next review starts, all agreed tag items shall be implemented in the 3D-CAD
model.
DEP 30.10.05.11-Gen.
February 2012
Page 11
4.
3D-CAD MODEL
4.1
GENERAL
The 3D-CAD model is a collection of graphical data which describes the facilities of a plant
or offshore installation for design and visualisation purposes.
The 3D-CAD model can be accessed via a 3D-CAD system. The graphical data is an
integral part of an engineering database supporting the design process.
The 3D-CAD engineering database enables the integration and consistency of the different
design stages and the different subjects, such as piping, foundations, tabletops, steel
structures, equipment, instrumentation, electrical equipment, buildings and Heating,
Ventilation and Air Conditioning (HVAC) equipment into one 3D-model.
Typical deliverables of a 3D-CAD system include:
a) Detailed engineering drawings such as plan and elevation drawings for piping,
structural, civil, instrumentation and electrical;
b) Plot plans;
c) Plot elevation drawings;
d) Piping isometrics;
e) Vessel trim isometrics;
f)
4.3
DEP 30.10.05.11-Gen.
February 2012
Page 12
4.4
INSTRUCTION
The 3D-CAD model may be used for training and instruction of plant operators, construction
staff, maintenance staff and emergency response organisation.
4.5
4.6
REQUIREMENTS
Where practical, the colours used in the 3D-CAD model shall be in accordance with
(Appendix I). The 3D-CAD design lead engineer is to advise if specific colour coding is
achievable. The Principal shall approve alternative colour convention.
Colour coding shall also be used to indicate the status of equipment, valves and piping
during the various model reviews (i.e. built according to final information or indicative only).
Category I Criticality
DEP 30.00.60.13-Gen.
ratings
of
valves
to
be
colour
coded
as
indicated
in
The 3D-CAD model shall be set up such that images of items can be presented separately
(e.g. when only steel structures are shown and all other items are suppressed).
For complex areas, separate review files of floors or smaller units should be set up to make
detail review possible.
DEP 30.10.05.11-Gen.
February 2012
Page 13
5.
5.1
5.2
CONSTRUCTION
In a 3D-CAD block model, the equipment, buildings etc. shall be modelled in a simplified
way.
All different types of components modelled, shall have their own colour coding (see
Appendix I).
Plant layout studies and piping studies form the basis of the model. These studies will also
establish pipe track widths, structures, etc. The routing of main electrical and instrument
cable trenches and access ways / roads should be shown.
5.3
5.3.1
Introduction
A block model should be set up during the Define Phase for one process unit or for multiple
process units inclusive or exclusive of the neighbouring facilities, buildings and structures.
Separation distances of the process and
DEP 80.00.10.11-Gen. and DEP 80.00.10.12-Gen.
utility
facilities
shall
conform
to
DEP 30.10.05.11-Gen.
February 2012
Page 14
5.3.3
DEP 30.10.05.11-Gen.
February 2012
Page 15
5.4.1
General
Team review members shall be given adequate notice (approximately 3 months and
confirmation 6 weeks) before the block model review date, and they shall be informed of
the location, duration, participants, type of review and the type and number of drawings,
which are the basic documents for the constructed block model under review.
Before a block model review starts, relevant documentation shall be made available to the
members of the review team for prior familiarisation, i.e., plot lay-out drawings and Process
Flow Sheets.
5.4.2
Tools
Plot lay-out drawings and all PFS and PEFS which have been used for the build-up of the
3D block model shall be present.
5.4.3
Team composition
A team leader from the Contractor shall be appointed who is fully familiar with the project
and the 3D block model. He shall guide the team through the model. The team leader shall
be responsible for the pre-reading material, the efficiency of the review process, for the
adequate recording of comments and for the subsequent follow-up.
Since the 3D block model shows the main separation distances between plants, storage
areas, buildings and main equipment inside plants which are the basis for a safe, operable
and maintainable complex, the model should be reviewed during the earliest stage of the
Define engineering activities by a team representing at least the following disciplines:
Process technology;
Operations;
Maintenance;
Plant lay-out;
Technical safety;
Civil/ Structural;
Human factors engineering;
Mechanical;
Electrical;
Construction;
Projects.
DEP 30.10.05.11-Gen.
February 2012
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5.4.4
Handling of comments
After the 3D block model review, the agreed comments shall be distributed to the
representatives and be implemented in the model. It should be agreed whether a second
review is required.
5.4.5
Execute phase 30 %
(Detail eng).
EPC phase 60 %
(Detail eng).
Line list
Preliminary info
No detailed info.
available
All 30 % review
comments included.
Critical lines
PEFS
Preliminary info.
Equipment
information
Basic information
available
Dimensions according
to vendor information
and nozzle info.
available.
Pipe
specifications
in 3D model
Piping specifications
not loaded in the
3D model (standard
specifications)
Pipe specifications
loaded in the
3D model
Pipe specifications
loaded in the
3D model
Modelled pipe
lines
Piping modelled to
standard
specifications
Piping modelled to
the project pipe
specifications as
loaded in the
3D model.
On the Define/ BDEP documents of the pre-Execute Phase, the completeness level shall
be indicated.
DEP 30.10.05.11-Gen.
February 2012
Page 17
5.4.6
5.5
5.5.1
General
In this paragraph checkpoints are given for the review of a 3D-CAD block model. The
checklist will help to improve quality and to identify and eliminate potentially hazardous
situations.
The scope of this checklist is applicable to oil refineries, chemical plants, gas plants,
exploration and production facilities (onshore and offshore), supply/marketing installations
and to specific items such as storage facilities and/or jetties, road/rail loading facilities and
complicated manifolds.
The checklist is comprehensive but should not be considered to be fully exhaustive.
Include the following considerations for each item mentioned in the scope of a 3D-CAD
block model.
5.5.2
5.5.2.1
5.5.2.2
Are roads properly defined with respect to their logical approach to unit(s)?
Consider also the Movements area, including its marine location and rail and
road connections. Include road dimensions, considering main roads
(unrestricted) and restricted access roads.
5.5.2.3
5.5.2.4
5.5.2.5
Is the location of the Utilities area logical and optimal in relation to the
process units?
5.5.2.6
Is the location of the Movements area logical and optimal in relation to the
process units?
5.5.2.7
5.5.2.8
NA
DEP 30.10.05.11-Gen.
February 2012
Page 18
5.5.2.9
5.5.2.10
5.5.2.11
Have main maintenance and storage areas been taken into account?
5.5.2.12
5.5.2.13
5.5.2.14
Have main crane locations and lifting paths been indicated in the model
5.5.2.15
Are the battery limit locations been identified and/ or any major interface
connection (i.e. large coolwater lines, firewater lines, etc.)
5.5.3
Process Units
General Layout considerations
5.5.3.1
Have separation distances within the plot area been taken into account?
Consider furnace, column, main equipment, flare, any vent outlet to 'safe
location', oil collecting area like sewers
5.5.3.2
Is the routing of the main piping in bridges and via trenches defined?
5.5.3.3
5.5.3.4
5.5.3.5
5.5.3.6
5.5.3.7
Are there sufficient maintenance access ways available towards large air
coolers
5.5.3.8
5.5.3.9
5.5.3.10
NA
DEP 30.10.05.11-Gen.
February 2012
Page 19
6.
6.1
60 % model review:
The actual process design as given on the PEFS should not be checked during the model
review. If the model review, however, leads to a more economical solution without
jeopardising the design functionality or safety, this change may be implemented and the
PEFS shall be made consistent with the 3D-CAD model. Such proposals shall be brought
to the attention of the project manager.
Mark on the 3D-CAD system or on the PEFS all the pipes, equipment and instrumentation
that have been checked and accepted.
Indicate the points that have not been accepted, to facilitate the review in follow-up checks.
Ensure that when a modification is proposed it suits its purpose, and does not conflict with
other requirements. Ensure that it is practical, safe, in accordance with the PEFS and also
economic. If in doubt, consult the appropriate specialists of other disciplines.
The checklist of (Appendix II) should be used during the model review. Note that the
checklist is not exhaustive and shall not overrule the detail design requirements contained
in the project specifications where appropriate. Detailed design requirements associated
with the checklist items can be found in the following documents:
Definition of temperature, pressure and toxicity
levels
DEP 01.00.01.30-Gen.
DEP 30.00.60.10-Gen.
DEP 30.00.60.13-Gen.
DEP 30.00.60.20-Gen.
DEP 30.00.60.18-Gen.
DEP 31.06.11.11-Gen.
DEP 31.25.00.10-Gen.
DEP 30.10.05.11-Gen.
February 2012
Page 20
Piping - General requirements
DEP 31.38.01.11-Gen.
DEP 32.31.00.32-Gen.
DEP 33.64.10.10-Gen.
DEP 34.13.20.31-Gen.
DEP 34.14.20.31-Gen.
DEP 34.17.10.30-Gen.
DEP 34.28.00.31-Gen.
DEP 35.00.10.10-Gen.
Area classification
DEP 80.00.10.10-Gen.
DEP 80.00.10.11-Gen.
DEP 80.00.10.12-Gen.
DEP 80.45.10.10-Gen.
DEP 80.47.10.30-Gen.
S28.001
S28.011
The progress of the model is expressed in the percentage completed compared to the final
engineering.
Reviews of the model shall take place when the engineering as reflected in the model is
30 %, 60 % and 90 % complete.
The line-up shall be followed systematically and strict attention shall be paid to details,
since seemingly minor items can cause accidents. Start, for instance, with an overall view
of the complete plant, then zoom in on the applicable plot and review unit by unit. For each
unit give an explanation of the functionality, point out the main equipment and the critical
pipe lines. Review the location philosophy, the maintenance access, safety routes and the
operatability of all equipment. Review the critical line routings and location of the valves.
Sub-contracted work and package Supplier equipment shall be shown in the model with the
same level of detail as described above. The main engineering Contractor shall translate
any engineering deliverables available from the above mentioned sub-contractors into the
plant 3D Model. Only in the case that the spec for package units identifies such for a
specific package unit, an alternative method shall be used. For this reason, a specification
for human factors engineering and review requirements should be set-up and discussed
with the Supplier during the bid clarification meeting.
6.2.
6.2.1
Location and orientation of all equipment (incl. supporting method, lifting lugs,
insulation) and all space consumers (incl. pulling volumes and future
extensions)
6.2.2
NA
DEP 30.10.05.11-Gen.
February 2012
Page 21
6.2.3
6.2.4
Platforms incl. stairs and ladders. Essential for operation maintenance and
escape.
6.2.5
Critical lines, from critical line list (Lines determining the location of equipment
and large size pipe determing the plot layout).
6.2.6
Plot determining piping / ducts (including all 6 in. and larger, routing only,
underground as well as above ground)
6.2.7
6.2.8
6.2.9
6.2.10
Blast walls
6.2.11
Bund walls
6.2.12
Maintenance access ways (All including their clash volumes) essential for main
access/ operation/ influence on safety. This includes a representation of main
maintenance equipment and trolleys and trucks as applicable
6.2.13
6.2.14
Concrete slabs, paving and roads (different load bearing capacities shall be
recognised).
6.2.15
Relevant floor slopes, where the fall is >50 mm (2 in) over the floor width
6.2.16
Package unit location and orientation (basic shapes and main components
recognisable inside these package units, the escape ways shall be defined).
6.2.17
6.2.18
Pipe racks and main pipe support structures, sleeper ways, culverts, etc.
6.2.19
6.2.20
Main electrical and instrumentation cable trays / racks [200 mm (8 in)] and
wider).
6.2.21
6.2.22
6.2.23
6.2.24
6.2.25
6.2.26
6.2.27
6.2.28
Major pipe-chases in structure and buildings (reserved areas for future piping)
6.2.29
6.2.30
6.2.31
6.2.32
DEP 30.10.05.11-Gen.
February 2012
Page 22
6.2.33
6.2.34
6.2.35
6.2.36
6.2.37
Interfaces for future extensions and space for future equipment to be taken
into account
6.2.38
6.2.39
6.2.40
6.3
DEP 30.10.05.11-Gen.
February 2012
Page 23
(Full time);
Operations
(Full time);
Maintenance
(Full time);
(Full time);
Technical safety
(Full time);
Civil / Structural
(Full time);
Projects
(Full time);
(Full time);
Construction engineer
(Full time);
Mechanical
(on call);
(on call);
Electrical
(on call);
Construction manager
(on call).
DEP 30.10.05.11-Gen.
February 2012
Page 24
6.4
6.4.1
6.4.2
6.4.3
Process and utility lines (2 in. and above) incl. supports, flow measurements
and main instrumentation
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
6.4.9
6.4.10
Permanent cranes, hoisting beams pad eyes, etc. (based on material handling
study)
6.4.11
Hoisting equipment, lifting beams, monorails and davits (hoisting and transport
devices for routine maintenance of equipment or components in excess of the
manual handling requirements contained in DEP 30.00.60.20-Gen.)
6.4.12
6.4.13
6.4.14
6.4.15
6.4.16
Pipe supports locations and types (physically supported), for piping 3 in. and
above and all critical piping. (supports for stress critical systems shall be based
on stress analysis calculations).
6.4.17
6.4.18
6.4.19
6.4.20
6.4.21
6.4.22
6.4.23
PSV Locations
6.4.24
6.4.25
6.4.26
6.4.27
NA
DEP 30.10.05.11-Gen.
February 2012
Page 25
6.4.28
6.4.29
6.4.30
Utility stations
6.4.31
6.4.32
6.4.33
Fireproofing
6.4.34
6.4.35
6.4.36
6.4.37
Silencers
6.4.38
6.4.39
6.5
(Full time);
Operations;
(Full time);
Maintenance;
(Full time);
(Full time);
Technical safety;
(Full time);
Civil / structural;
(Full time);
Projects;
(Full time);
Instrumentation;
(Full time);
Electrical.
(Full time);
Construction engineer
(Full time);
(Full time);
Construction manager.
(On call).
Other relevant specialists should be consulted if required (e.g. fire safety and rotating
equipment).
Discussion of implementation of agreed comments from the 30 % reviews shall be part of
the 60 % model review.
The 60 % model review checks whether the physical layout is in line with the PEFS.
The human factors engineering design analysis results shall be used as input to the 60 %
model review.
DEP 30.10.05.11-Gen.
February 2012
Page 26
The Contractor shall perform a full line-by-line check against the latest revision of the
Process Engineering Flow Schemes, prior to the formal 60 % model review. Contractor to
confirm well in advance of the 60 % model review, that PEFS check has been performed
and which deviations have been identified. The Principal will perform a random check to
verify the quality of the model.
Contractor shall inform the Principal prior to the 60 % model review on:
6.6
6.4.1.1
6.4.1.2
6.4.1.3
6.4.1.4
6.4.1.5
Model shall be in accordance with the latest issue of the PEFS, linelist,
structural, civil, instruments and equipment vendor drawings
6.4.1.6
NA
DEP 30.10.05.11-Gen.
February 2012
Page 27
6.4.1.7
6.4.1.8
6.4.1.9
6.4.1.10
6.4.1.11
Instrument junction boxes, local control panels and instrument support stands
6.4.1.12
6.4.1.13
6.4.1.14
Final lighting
6.4.1.15
Transmitter boxes
6.4.1.16
Sample stations
6.4.1.17
6.7
DEP 30.10.05.11-Gen.
February 2012
Page 28
7.
ARCHIVING
DEP 30.10.05.11-Gen.
February 2012
Page 29
8.
REFERENCES
In this DEP, reference is made to the following publications:
NOTES:
1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards.
SHELL STANDARDS
Definition of temperature, pressure and toxicity levels
DEP 01.00.01.30-Gen.
DEP 30.00.60.10-Gen.
DEP 30.00.60.13-Gen.
DEP 30.00.60.20-Gen.
DEP 30.00.60.18-Gen.
DEP 31.06.11.11-Gen.
DEP 31.25.00.10-Gen.
DEP 31.38.01.11-Gen.
DEP 32.31.00.32-Gen.
DEP 33.64.10.10-Gen.
DEP 34.13.20.31-Gen.
DEP 34.14.20.31-Gen.
DEP 34.17.10.30-Gen.
DEP 34.28.00.31-Gen.
DEP 35.00.10.10-Gen.
Area classification
DEP 80.00.10.10-Gen.
DEP 80.00.10.11-Gen.
DEP 80.00.10.12-Gen.
DEP 80.45.10.10-Gen.
DEP 80.47.10.30-Gen.
S28.001
S28.011
DEP 30.10.05.11-Gen.
February 2012
Page 30
APPENDIX I
1.
2.
3.
PIPING
Process:
Liquids
Gas
Brown
Light Green
Steam/condensate
White
Flushing oil
Brown
Yellow
Brown
Cooling water
Green
Blue
Nitrogen
Orange
Relief/drain/slops
Black
General purpose
Purple
Fire-fighting water
Category 1 Valves
Red
Yellow
Beige
Black
Green
Light Blue
Pink
Steel blue
Concrete
Light grey
Mechanical equipment
Dark grey
Electrical equipment
Green
Yellow
Red
Blue
Green
Red
White
For all other items, the choice of the colour coding is at the discretion of the Contractor.
DEP 30.10.05.11-Gen.
February 2012
Page 31
APPENDIX II
In this appendix, checkpoints are given for the review of a 3D-CAD model. The checklist will
help to improve quality and to identify and eliminate potentially hazardous situations. The
checklist shall be read in close consultation with the appropriate project design
specifications.
The scope of this checklist is applicable to oil refineries, chemical plants, gas plants,
exploration and production facilities (onshore and offshore), supply/marketing installations
and to specific items such as storage facilities and/or jetties, road/rail loading facilities and
complicated manifolds.
The checklist is comprehensive but should not be considered to be fully exhaustive.
1.
1.1
1.2
Check proper escape routes from elevated equipment and all platforms.
Check that at least two exits are present on every platform with a blind length
of over 7 m (23 ft) long. This applies for platforms at structures, around and
underneath air-cooled heat exchangers, vessels, on top of furnaces and
frequently used working areas by maintenance. Have ladders and staircases
been installed on the outside of structures?
1.3
Check that there are no obstructions in the path of escape ways and that
escapes ways are as straight as practical. Ensure the exit is directed away
from a process area. All staircases should route at ground level to an open
area to allow an unobstructed escape way.
1.4
Check that there are no head knockers, shin splitters or tripping hazards.
1.5
1.6
Check for proper smooth connections between platforms and table tops.
1.7
1.8
Check that operators manipulating drain valves of open drain systems can
see the drained effluent. Provide tundishes as required.
1.9
1.10
Check if utility stations have been provided at the main operational platforms,
especially at columns operating at high temperatures, so that steam lances
can be connected to tackle small leaks
1.11
1.12
Check that there are no open sewer pits near hot pumps, furnaces, etc.
NA
DEP 30.10.05.11-Gen.
February 2012
Page 32
1.13
Check that steam exhaust cannot cause personnel hazards, either from
spraying droplets of hot water or by causing icy or wet surfaces.
1.14
1.15
1.16
Check that inlet valves of silencers on steam pipes for warming up or start up
are operable in a safe manner without risk of pouring hot condensate from
the silencer outlet on the operator below.
1.17
Are hot and cold pipes and surfaces near walkways properly insulated for
personnel protection?
1.18
Check that the suction of the air blower of an analyser house or control room
is taken from a non-hazardous area.
1.19
Are hoisting devices provided for parts that weight in excess of the manual
handling requirements?
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
NA
DEP 30.10.05.11-Gen.
February 2012
Page 33
2.11
Check whether the layout of water spray pipes and nozzles is adequate to
cool LPG vessels.
2.12
Are fire detectors and tubing present on hot pumps and LPG pumps?
2.13
Are detectors for fire, gas, smoke and H2S strategically located?
2.14
Are warning and alarm lights for fire, gas, smoke and H2S strategically
located?
2.15
Are fire water deluge manifolds safely located in relation to the equipment
they protect?
2.16
2.17
2.18
PIPING
3.1
Is piping entering and leaving the plant logically grouped together at the
battery limit?
3.2
3.3
3.4
3.5
Are start-up and circulation pipes short? Have dead ends been avoided?
Can the system be flushed and drained?
3.6
Do vapour pipes, including steam pipes, freely branch off from the top of
main pipes?
3.7
Can piping subject to thermal expansion indeed expand? Check that nozzles
and branches (e.g. instruments) on expanding piping do not touch
obstructions, such as support beams.
3.8
Look for pockets in vapour pipes where condensation may occur. Has
external heating been applied on those pockets which cannot be avoided?
3.9
Are long small diameter pipes (e.g. instrument impulse pipes) supported
properly to prevent breakage due to vibration?
3.10
Check for adequate space and jacking facilities to remove man-hole covers,
especially for those with inserts.
NA
DEP 30.10.05.11-Gen.
February 2012
Page 34
3.11
Pipes should not pass through table tops. Where this cannot be avoided,
ensure a protective kerb is provided around the open area to prevent any
rainwater or oil entering the area below. All rain water disposal pipes from a
table top shall be extended to ground level.
3.12
Have dead end sections been avoided, e.g. in steam and water pipes and in
pipes with high pour point material?
3.13
3.14
Check the position of eccentric reducers. Normally, the straight part is on the
bottom of horizontal pipes, except in pump suction pipes where vapour
pockets may cause cavitation of the pump.
3.15
Do compressor suction pipes slope towards the knock-out drum? Each low
point of the compressor suction should have a low point drain.
3.16
Check that small bore cooling water pipes emerge from the top of the
header.
3.17
Are stripping steam pipes short and horizontal, or sloping from the last
valve?
3.18
Verify that two-phase flow vertical piping has been checked for flow stability,
also for the turndown case.
3.19
Check absorber gas feed inlets for pockets near the inlet to avoid absorbent
entering the gas inlet pipe.
3.20
3.21
3.22
3.23
3.24
Are maximum angles with the vertical as specified for piping containing
solids adhered to?
3.25
Have special provisions for commissioning and initial start-up been properly
addressed? (e.g. temporary large blow spools and silencers).
3.26
3.27
Check for appropriate clearance around flanges, piping and valves. As per
DEP 31.38.01.11-Gen. and DEP 30.00.60.13-Gen.
DEP 30.10.05.11-Gen.
February 2012
Page 35
4.
VALVES
4.1
4.2
4.3
Check that there are no valves installed with the stem pointing downward.
4.4
Are hand wheels easily accessible for operation and not obstructing
walkways or platforms? (Consider the stems, especially when in the open
position.)
4.5
Are valves for emergency operations operable from grade level? Are valves
that need frequent attention easily accessible?
4.6
Check for valves in vertical pipes which may accumulate liquid (e.g. water
or condensate).
4.7
Check that control valve assemblies are located at ground level or on the
first platform, except when otherwise required for process reasons.
4.8
4.9
4.10
Have spring-loaded and/or extra block valves been used where valves may
freeze up when draining or sampling?
4.11
Check that stripping steam pipes to columns have a drain pipe for
condensate removal and a vent pipe near to the column.
4.12
Check that the status of vent and drain valves used for instrument
maintenance or for decommissioning of plant during turnarounds, as well as
those used for operational venting and draining shall be clearly visible from
the operator vantage point at access platforms and walkways.
5.
5.1
5.2
Check whether bundles can be pulled and lowered safely from platforms
and stacked exchanger arrangements.
5.3
Check stacked heat exchangers for the possibility of oil spills on hot heat
exchangers or other equipment beneath, especially during maintenance
work. In this case, consider a large oil collecting funnel underneath, or
check the possibility to take both out of service.
5.4
Check if the drain and vent valves are correctly located as specified on the
PEFS, hence drains at lowest points and close to the block valves if so
specified.
5.5
Check whether cranes, bundle pulling equipment and cars can enter for
pulling and transportation of bundles.
5.6
Check whether heat exchangers can be cleaned in situ. Are the required
provisions present (e.g. valves, cleaning pipes, etc.)?
NA
NA
DEP 30.10.05.11-Gen.
February 2012
Page 36
5.7
Check that exchangers in LPG service have been provided on the water
outlet side with a vent pipe to a safe location to allow gas to escape in case
of tube leak.
6.
6.1
6.2
Can the pump and compressor safely be handled for maintenance such as
filter pulling? Pay special attention to spading-off possibilities and draining
of the casing and the strainer.
6.3
6.4
Ensure that steam tracing around the suction and discharge pipes can be
dismantled to allow pump removal.
6.5
Is the flow in suction piping smooth? Check for the required straight length
of the suction pipe for double-suction pumps.
6.6
6.7
Check volumes which must be drained when a filter or the pump needs to
be opened. If the volume is very large, enlarge the size of drain valves to
achieve a reasonable draining time. Also check that the drain piping of
filters and casing is short and straight.
6.8
For pumps with a vertical suction pipe and an elevated strainer, check that
opening of such a strainer does not result in spilling flammable liquid and
possible ignition on nearby hot surfaces.
6.9
Are pump priming facilities adequate? Is the vent valve at the highest point
at discharge and suction side?
6.10
6.11
Are compressor seal oil tanks provided with their vents to the atmosphere at
a safe location?
6.12
Are lube oil storage drums properly protected against ingress of rain water
and is the storage area properly drained?
6.13
6.14
Are compressors with bottom inlet pipes at the suction provided with liquid
drains to a closed system?
6.15
6.16
6.17
6.18
NA
DEP 30.10.05.11-Gen.
February 2012
Page 37
7.
7.1
7.2
Check that piping does not obstruct observation windows, access doors,
header box covers, etc.
7.3
Is space available for withdrawing and cleaning tubes? Is there space for
cranes to enter and manoeuvre?
7.4
7.5
NA
NA
Are heavy fuel and LBF (low boiling fuel) systems sufficiently
segregated?
Are adequate provisions made to prevent liquid fuels from
entering atomising steam and steam-out pipes?
Are low-points in fuel gas pipes avoided between the fuel gas
knock-out vessel and the burners or has tracing been
provided?
Are locations of flame arrestors, straight pipe lengths, etc. of low pressure
and waste gas in accordance with specifications?
7.6
7.7
Make sure that dry emergency or smothering steam is made available, with:
outlet branches positioned on top of mains;
steam pipes without pockets;
sufficient steam traps and drain points provided.
7.8
On manually-started furnaces, are fuel valves of fuel oil and fuel gas within
reach when looking at the burners through the observation windows?
7.9
7.10
For multiple furnaces: check for a logical and clear layout of each furnace
and its local start-up panel.
7.11
Can a furnace be spaded off at its flue gas duct for furnace entrance and
repair? This is required when multiple furnaces are connected to a common
flue gas duct and one of the furnaces is required to continue to operate.
8.
8.1
Check for unnecessary dedicated drain piping (e.g. where draining a vessel
or column to grade can be done via existing piping such as drains of
pumps).
8.2
8.3
Are instrument tappings and local instruments and level glasses readily
accessible? Note that a levelglass on a vessel or column actually may
protrude 500 mm (20 in) into the platform area and thus form an
unacceptable obstruction.
8.4
Check that instrument support poles, such as those used for pressure
transmitters, are not obstructing a walkway of a platform around a column.
DEP 30.10.05.11-Gen.
February 2012
Page 38
8.5
8.6
Can the pipes follow the expansion of the equipment when heating up and
cooling down? Pay special attention to supports on both hot and cold
structures.
8.7
8.8
8.9
Check that the barometric seals of vacuum equipment are at the specified
height. This also applies for relative elevations of vessels belonging to a
vacuum system.
8.10
For columns with structured packing, ensure there is a steam and water
hose connection point nearby to fight any spontaneous fire when opening
the manholes.
9.
9.1
Flare pipes shall have no pockets and shall slope continuously to the flare
knock-out drum. If a low point is unavoidable, ensure a drain with adequate
size is connected to a drain vessel.
9.2
Are flare headers provided with an end blind flange or manhole entry point
to allow for inspection and internal cleaning?
9.3
If a platform is installed for spading a part of the flare pipe whilst the main
flare pipe is still in use, ensure that there is enough space to do the work.
Check that there is a proper escape way from this platform.
9.4
Check that inlet pipes to relief valves are self-draining into process
equipment. Relief valves should be located on the main process header.
9.5
Check that outlet pipes from relief valves are self-draining into the flare
header. An exception may be made for liquid (DN 25 DN 25) thermal relief
valves which do not need to be self-draining on both sides if the pipes
would become too long. Check that connections are made on top or on the
side of the flare header.
Ensure that process relief valves and process thermal relief valves are not
routed to grade. They should end in a closed system.
9.6
Check the accessibility of relief valves sets for maintenance and inspection.
Have relief valves been installed at proper elevations relative to the flare
header? All relief valves should be accessible for removal (by hoisting
equipment if necessary).
9.7
9.8
9.9
9.10
Check relief valve outlet pipe arrangements such that supports can be
provided to cope with reaction forces.
9.11
NA
DEP 30.10.05.11-Gen.
February 2012
Page 39
9.12
Is the distance from the flame arrestor to the vent outlet as specified?
Ensure that flame arrestors in pipes to the atmosphere can be accessed for
removal and maintenance.
9.13
Check that the spindles of flare main block valves, if gate valves, are in a
horizontal position. This prevents a blocked flare pipe if the wedge should
fall down.
10.
OIL MOVEMENTS
In addition to the above checkpoints, the following shall apply for oil
movements installations.
10.1
10.2
10.3
10.4
Are tanks and bund areas accessible for fire fighting equipment?
10.5
10.6
10.7
10.8
Jetties: are adequate working envelopes provided for hoses and loading
arms and is the width of the jetty sufficient for the required equipment?
10.9
For tankfarms and pipe tracks: can rainwater and spilled oil be drained
adequately?
10.10
10.11
10.12
11.
ENVIRONMENTAL CHECKS
11.1
11.2
11.3
11.4
11.5
Are drains from sample points of plants and storage tanks minimised by, for
example, closed loops?
11.6
NA
NA
DEP 30.10.05.11-Gen.
February 2012
Page 40
11.7
Check drainage from heat exchangers when opened for bundle cleaning or
repairs. Consider also the effect of liquid spillage when opening both heads
as well as when pulling the bundle.
11.8
Check drainage of sour or spent seal and lube oils from compressors.
11.9
Check drainage from pipes at the battery limit prior to spading the unit.
11.10
11.11
Check that liquid collected in an open oil collecting pit inside the unit is
prevented from evaporation, e.g. by covering with a closed plate.
11.12
11.13
11.14
Check that the distance around plants is in accordance with any local
regulations, including noise limitations.
DEP 30.10.05.11-Gen.
February 2012
Page 41
Height
Angle
DEP
80.00.10.11/
31.38.01.11
30.00.60.20
Stair
80.00.10.11/
31.38.01.11
30.00.60.20
Handrail
80.00.10.11/
31.38.01.11
30.00.60.20
Safety route
80.00.10.11/
31.38.01.11
Valve position
80.00.10.11/
31.38.01.11/
30.00.60.13
31.38.01.11/
30.00.60.20
31.38.01.11/
30.00.60.20
80.00.10.11/
31.38.01.11
80.00.10.11/
31.38.01.11
General