Professional Documents
Culture Documents
1. Introduction
2. General
3. General Safety
4. Lines
5. Valves
6. Heat Exchangers/Reboilers
7. Pumps and Compressor
8. Vessels/Columns
9. Furnaces/Boilers
10. Relief System
11. Electrical
12. Instrumentation
13. Civil/Structural
14. Attachments
1. Introduction
The purpose of this document is to lay down a review procedure to ensure that the desired level of quality for the creation of a
piping 3D is carried out in the engineering office and that sound design criteria for operability, safety and maintenance have
been observed.
This check list may also be used for the recording of the check, appropriate space is left for any comments against a checked
item in column “remarks”.
Additionally the form “Internal 3D Model Review” (see Attachment 1) and the form “Approved 3D Model Revisions from
Internal 3D Model Review” (see Attachment 2) may be used for reporting purposes.
2. General
Check if “Interference Checking” facility has been run, if so, ask to see a printout of the report.
Check the 3D model against the latest issue of the plot plans, engineering and utility flow diagrams and line tables.
Follow the line up systematically and pay strict attention to details since many accidents are caused by seemingly minor
items.
Mark on the engineering flow diagram all the lines, fittings and instrumentation which have been checked.
Make sure that when a modification, addition, elimination or reduction is considered, that is suits its purpose, is practical and
also economical. When is doubt consult others.
Use this procedure for a number of items which can not be shown on diagrams. Please note that the checklist does not
pretend to be complete and under no condition it shall overrule sound judgment.
Check that the color code has been used correctly.
Check if construction can build the unit(s) economically as designed.
Check that start up and shutdown problems have been considered and drain and let-down facilities have been provided.
Check the accessibility for operation, maintenance with mobile equipment and inspection.
Check location of future equipment.
Check location of drop out areas.
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3. General Safety
Check that fire hydrants are not positioned at the ends of, or in the line with the ends of, horizontal vessels.
Check elevated equipment’s and platforms for the proper escape routes. Ensure unobstructed and short escape routes at
grade.
Check that ladders and staircases have been installed on the outside of structures. Are staircases provided with turnaround
landings?
Does escape traffic have to pass through structures? Check companies and/or governmental regulations for safety.
Check that remote shutdown and valve closing devices are installed at safe locations. Check that equipment concerned can
be seen from these locations.
Check for “chimney gasp” between platforms and/or table tops.
Check that safety showers and eye baths are located near equipment containing aggressive chemicals (e.g. caustic, ADIP,
MEA, HCl, h4SO4, etc.).
Check accessibility of the unit for mobile fire-fighting equipment and rescue work.
Avoid head bumpers, shin splitters and tripping hazards.
Check that emergency/smothering steam header block valves are at safe distance from protected equipment (e.g. in
hydrogen service or near fired heaters). A steam header block valve station could be fire shielded, if required, by brick or
concrete wall.
Make sure that operators manipulating drain valves can see the emerging affluent. The required level gauges shall be visible
and funnels must be provided.
Check that water trapped in goosenecks cannot be displaced by hydrocarbons.
Check that utility stations have been provided, including those at the main operation platforms, e.g. for the connection of
steam lances.
Check barometric seal height of vacuum for liquids other than water. Ensure that the liquid can be drained as well. Important
for the design of the structure elevation.
Check that platforms have been provided at places where work is expected between maintenance stops.
Check that steam exhaust cannot cause personnel hazards either from spraying droplets of hot water or causing icy or wet
surfaces.
Check that steam rings are foreseen at flanges in overhead lines of thermal cracking units and for lines in hydrogen service.
Be alert for equipment supported on continuous platforms when sections of these platforms are supported on structures
subject to different thermal expansion.
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Check that continuously operating vent stack are higher than the highest nearby structure (within a safe distance).
Check the location of liquid relief valves, since its actual height influences the required set pressure.
Check the location of toxic gases (h4S, VCM etc.) monitoring points if applicable.
Check that drains of light hydrocarbons (propane, butane) are protected against freezing (e.g. double valves).
Check that firewalls have been located correctly.
Check that levers of plug-and ball valves are not hampering operators on walkways or platforms, levers shall move in the
same plane as the piping lay out.
Check that steam for purging of lines and equipment (e.g. snuffing steam, emergency steam) is dry, provide automatic trap
stations with drain assembly upstream of last block valve in steamline.
Check that process ventlines are routed and oriented to safe locations, (3 meter above highest platform), watch nearest
platforms and prevailing wind direction.
Check location of manholes with platforms and ladders in respect to safe escape route.
In case of location of water cooled equipment at high elevated platforms, check if the normal cooling water pressure is
suitable for this duty, otherwise a booster pump shall be installed.
To prevent vacuum in equipment located at high elevations, due to siphon operation of the fluid, install a vacuum breaker to
suck in air or a process gas.
4. Lines
Check that piping entering and leaving the unit is logically grouped together.
Check that valves, blinds, flushing/drain and instrument connections are properly located. Check especially so called
manifolds and large control valves. Check in cases where spades are used ISO spectacle blinds, that piping system are
flexible enough to insert these spades.
Check that piping subject to thermal expansion is anchored at plot limits.
Check elevation of overhead piping and horizontal clearance of access and/or walkways.
Check that start-up/circulation lines are short.
Check that dead ends have been avoided. Check if system can be flushed and drained.
Check that vapor lines (inclusive steam) branch off from the top of main lines. Prevent pockets in vapor lines. Keep lines
sloping to a drum or install drainpoints (driplegs).
Check that piping subject to thermal expansion is flexible enough. Are supports adequate?
Check if nozzles and branches on expanding piping are not installed near obstructions, support beams, etc. (to avoid ripping
off). Are these lines properly anchored. Are stresses on equipment nozzles within limits.
Check for pockets in vapor lines where condensation may occur. Has external heating been applied on those pockets which
can not be avoided?
Check that long lines attached to small bore nipples are properly supported to prevent breakage due to vibration.
Check that lines do not pass through table top, but run alongside. If impossible group lines together passing via a sleeve.
Check that dead end sections have been avoided (e.g. in water lines).
Check that piping has been designed to permit easy drainage, venting, flushing, testing, maintenance, insulation, painting.
Check position of eccentric reducers. Normally straight side on bottom of horizontal lines except in pump suction lines where
vapor pockets may cause calibration in the pump.
Check that compressor suction lines slope toward knockout drum.
Check that small bore cooling water lines branch off from top of the header. (This to prevent plugging).
Check that stripping steam lines are short and horizontal or sloping from the last valve.
Ascertain that two phase flow vertical piping has been checked for flow stability.
Check that hydraulic (water) hammer conditions have been checked.
Check that all lines have been properly numbered.
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Check that high temperature and special material lines have been stress analyzed.
Check that gas is prevented from entering cooling water system.
Check absorber gas feed inlets for pockets near the inlet to avoid absorbent in the gas line.
Check that piping with instrument connections has been laid so that these connections are easily accessible. Check if
necessary platforms and walkways have been provided.
Check anchoring of piping discharging to atmosphere. Pay special attention to screwed piping.
Check that vacuum equipment steam jets has been hooked up directly to the steam mains, i.e. without any intermediate
connections which may suck in air. This is not applicable for vacuum pumps.
Check (for the same reason) that venting of the gas compressor suction piping has been avoided.
Check all coordinates on piping for correct configuration and clearances.
Check that service stations have been properly located. Design also for winterizing (water/steam/air in one insulated box).
Check for rotary equipment that suction and discharge piping are properly supported.
Check clearance between piping and structural steel with fireproofing.
Check that thermosiphon reboilers have been located such that minimum pipe distances and equal vapor distribution are
achieved.
Check required straight piping runs to distributor piping in distillation columns. Only in vertical plains are bends allowed within
this straight run.
If a vent is required on an exchanger for periodically purging of noncondensable vapors, this vent valve shall be accessible,
vent plus line shall be shown on 3D model.
Check piping arrangements on shell and tube side of exchangers carefully for correct flow of fluids and proper operation of
exchangers.
If symmetrical piping hook up is required to exchangers, airfines or double suction of pump, check this carefully.
Keep length of suction piping to pumps to a minimum and prevent pockets.
Check location of break flanges on piping at shell and tube exchangers and aircoolers to facilitate bundle removal.
Check that number of passes in a heater are shown and if necessary check that piping is symmetrical.
Check that location of isolating valves and valves of snuffing steam and emergency steam are at 15 meter distance from the
heater at grade and accessible.
Avoid dead legs in heavy fuel oil lines and waste gas lines.
In case of steam jacketed sulphur lines provide T-pieces or cross pieces at the end for cleaning the sulphur lines by rigging.
Check location of relief valves and their good accessibility for servicing.
Check location of local panels for safe operation and good accessibility.
5. Valves
Check that valves in overhead pipe tracks have been avoided to the maximum extent.
Check that chain operated valves have been avoided where possible.
Check that all valves are installed with the steam installed with the stem pointing upwards or horizontally.
Check that hand wheels are easily accessible for operation and yet not obstructing walkways or platforms.
Check also steams, especially in open position.
Check that valves for emergency operations are workable grade level.
Check that valves that need frequent attention are easily accessible.
Check valves in vertical lines for possible water traps.
Check when reduced port valves are installed, that piping is self draining on both sides of the valve.
Check that hot oil block valves are well accessible in view of fire risk.
Check that control valve assemblies are located at ground level or on first platform (except when required otherwise for
process reasons).
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Check that installation of valves outboard of elevated platforms has been avoided.
Check that valves or double block and bleeders have been installed in utility connections to process equipment and lines.
Check that spring loaded and/or extra block valves have been used where valves may freeze-up when draining or sampling.
Check that process vents and drains are shown.
Check location /installation of check valves in ditch. lines of pumps or near connection of lines, for example connection of
condensate lines from traps to condensate collecting header near to the header.
Check levers of plug-or ball valves, these shall not obstruct walkways, platforms etc. Levers shall move in the same plane as
the piping lay out.
6. Heat Exchangers/Reboilers
Check that piping arrangement is acceptable with respect to the removal of shell and channel covers as well as the
withdrawal of tube bundles.
Check whether bundles can be pulled and lowered safely from platforms and stacked arrangements (obstructions, hydrants).
Check stacked heat exchangers for the possibility of oil spills on hot equipment beneath it, especially during maintenance
work.
Check accessibility to exchangers for maintenance, bundle removal/cleaning, etc.
For a thermosiphon check reboiler check the elevation difference between draw-off pan and reboiler for driving force
If a vent is required on the exchanger for periodically purging of noncondensable vapors, this vent valve shall be accessible.
Vent also to be shown on 3D model
Cold fluid enters the exchanger at the bottom and leaves it from the top
Check crane access to airfin coolers for maintenance or construction.
Check symmetrical piping hook-up to several bundles in an airfin cooler or to exchangers in parallel operation. Dead legs in
capped headers shall be kept to a minimum or be avoided, use elbow ISO tees at the end of the header. Pockets in outlet
piping of aircooled or water cooled condensers must be avoided as well as in the hot vapor bypass lines.
Straight length from suction flange until bend to be 3D (D = diameter nozzle pipe), no reducer allowed.
In vertical pipe reducer, strainer and valve can be installed.
For top inlet straight length = 5D if suction line runs in length direction of pump motor and 3D if suction line runs in
same plane as pumps impeller(s). Upstream of the bend in the suction line the strainer, valve etc. can be installed.
Check that pump operating under vacuum are provided with high point vents, which are connected via a vent line to the top of
suction vessel
For a vertical pumps no straight length is required.
If pump handle liquids with temperatures above auto-ignition, this pumps shall be located in safe-areas (not underneath pipe
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rack) and widely spaced from other pumps. Good accessibility for fire fighting is required and above pumps a sprinkler
system shall be installed
Piping to compressors. Pockets shall be prevented, lines shall be slope to suction drum and suction line shall mostly be
steamtraced. Check vendor drawings carefully
Check all flushing, cooling, quenching requirements of pumps and compressors
Check that sufficient space is available for removal of filters from strainers
Suctions lines of pumps to be of minimum length
Check NPSH of pumps
If two pumps are parallel operating the piping hookup at suction and discharge side shall be symmetrical.
On reciprocating compressors safety valves must be located upstream of the discharge block valve.
8. Vessels/Columns
9. Furnaces/Boilers
Check that piping does not obstruct observation windows, access doors, header box covers, etc
Check that space is available for tube withdrawal and cleaning
Check that piping at burners is arranged so that insertion/removal of lighting torches and burner guns is not hampered
Pay special attention to safety of fuel system:
Check that heavy fuel and LBF system are sufficiently segregated
Check that provisions are made to adequately prevent liquid fuels from entering steam and gas system
Are locations of flame arrestors, straight pipe length etc. of low pressure and waste gas in accordance with
specifications?
Check that emergency/smothering steam valve manifolds are at safe distance. Steam shall be dry. Install upstream of
manifold at low point a drain valve and automatic steam trap
Check that dry emergency steam is available
Check that :
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Check that fuel and atomizing steam cocks are within hand reach when looking at the burners through the observation
windows
Check that the local emergency shutdown switch is at a safe location
Check that safety logic (for heater start-up and shut-down) is not located below (vertical) furnace. Normally such a logic is
located in a local panel at safe distance (15 meter) from a fired heater
One complete burner hookup shall be shown per heater including all instruments and all provisions for safe startup, operation
and shutdown of the heater with associated equipment (e.g. fans).
Check final certified vendor drawings for equipment correctness.
Check prescribed safety distances, e.g. for example:
Check that inlet lines to relief valves are self draining into process equipment.
Is its proper functioning not hampered by the nature of the process fluid? The allowable pressure drop across the inlet line of
relief valve is limited to 3% of the set pressure (at maximum capacity). If pressure drop is too high, the line size shall be
increased.
Check accessibility of the relief valves for maintenance and inspection. Check if relief valves have been installed at proper
elevations. Distinguish between valves releasing to atmosphere or relief deader.
Check pressure relief discharging to atmosphere for safe location and direction.
Check that discharge pipe is drainable. If so, does drain not impinge on other equipment? Have measures been taken to
avoid freezing of moisture on relief valve seats in low temperature service?
Check tail pipes for adequate support against reaction forces.
Check that the tail end of vent pipe is within the action radius of fire extinguishing equipment. If not, has a snuffing steam
connection been provided?
Check that length of piping is minimized for safety relief valves discharging into a closed system.
Check that outlet line from relief is self draining into flare header. Check if connections are made on top of the flare header.
Check that flare lines have no pockets and that they are sloping to the flare knockout drum.
The back pressure on the relief valves (calculated during the design) shall be checked with the actual layout of the flare
system.
Check destination of outlets from 1 ”x 1” thermal relief valves to atmosphere or grade for safety.
In case hooked up to the vessel, check if steamtracing is required to prevent plugging.
Check locking devices of the valves at inlet/outlet of the relief valves.
Check that valves with Castell lock system (or other system) are properly installed.
Check that safety relief valves and inlet/outlet lines adequately supported.
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Check that tail pipes of relief valves require weather protection cap.
Check that the proper type of the relief valve has been specified, for example in waxy service piston type in view of plugging.
In case of 1 ”x 1” thermal relief valves, the inlet of the relief valve shall be self-draining to the process line, the discharge line
can be connected to a collecting header which shall be discharging under slope without pockets to a vessel. Check if inlet
and outlet lines of relief valves shall be steamtraced.
11. Electrical
Check that cable trunkings are properly located and not obstructed by equipment etc.
Columns of pipe racks are normally used to install junction boxes for both electrical and instrumentation purposes.
Check that orientation and access is not hampered by location of control valve station, steamtracing stations, utility stations
or other piping lay-outs.
12. Instrumentation
Check that all instruments are on 3D model and have been correctly tagged.
Check that instrument cable trunkings are properly routed and in accordance with applicable instrument drawings.
Check that local control panels, main junction boxes, etc. are properly located.
Check location and accessibility for operation and maintenance of all instruments. Mind removable piping on both sides of
reactors (swing elbow), here special design is required.
Check straight length of orifice runs.
Check clearance above external displacers for removal of floats.
Check platform clearance around level gauges, control valve stations, relief valve station, especially for Camflex type control
valves with bypass.
Show all personnel protection, gas detection points (sniffing points).
13. Civil/Structural
Check that all structures with bracing and pipe racks are shown, inclusive fireproofing.
Check that all plinths for equipment and structures are shown.
Check that all table tops are shown.
Check location of analyzer house(s), if fast loop requirements for correct measurements (samples) will be met.
Check that bracing of steel does not form an obstruction.
14. Attachments
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Definitions
BASIC
30% Completion
60% Completion
90% Completion
100% Completion
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