Engineering Procedure

SYRIA

MECHANICAL DESIGN
CHECK LISTS

Controlled Document No. : 3.OEE.3.144 Custodian : OEE/1

Originated by : Verified by : Approved by : Revision & Date :

OEE/1 OEC/2 (static only) OES Rev 00 - 25/06/03

OEE OES/D
OEC (static only)

Reason for Revision : New procedure

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Contents

Page
1. OBJECTIVE 3

2. FACILITIES ENGINEERING - PIPING/LAYOUTS 3

3. CHECKLIST FOR MECHANICAL EQUIPMENT 4

3.1. General (Applicable to All Items) 4
3.2. Pumps 5
3.3. Centrifugal Compressors 6
3.4. Gas Turbines 7
3.5. Instrument Air Compressors 8
3.6. Heat Exchangers 8
3.7. Pressure Vessels 9

4. HVAC CONCEPTUAL DESIGN CHECK LIST 9

5. MAINTENANCE CHECKLISTS 11
5.1 Maintenance Execution 12
5.2 Special Tools 12

1. OBJECTIVE

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The purpose of these checklists is to provide support for Mechanical Discipline Engineers
involved in completing Technical Design reviews.

It may also be used by Field staff and Project Engineers as a 'reference' document for
undertaking design document review responsibilities. However, individuals may wish to
extend the coverage of each section to accommodate specific requirements. It is not
issued, nor it is intended to be used, as a fully comprehensive list of checks/reviews
covering ALL circumstances.

Review of the design documents should ensure that the correct interpretation of the
Scope of Work and Technical Specifications is made, a suitable approach is established
to the design, the correct procedures, Codes and calculation methods are used,
Technical Competence is adequate and correctness in calculations is achieved.

2. FACILITIES ENGINEERING - PIPING/LAYOUTS

Is the piping and fitting specification in line with schedule Q.

Are the piping and fitting manufacturers on our AML (Approved Manufacturer List)
Are the buying descriptions in line with the CMT.
General (specific lists for particular areas may be developed if required)
Availability of all documents to be reviewed.
Correct pipe class, dimensions, areas.
Equipment layouts for allowance for associated pipe work, valves, controls.
Equipment layouts for accessibility for operation, maintenance and removal of major
components, or complete unit removal as appropriate.
Material and equipment handling routes.
Equipment arrangements with respect to:
- existing equipment and systems;
- tie-ins;
- commissioning;
- operability;
- hazardous areas;
- minimum pipe runs;
- minimum cable runs;
- minimum disruption to normal plant operation.

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Drawing format and title block details.

Cross check equipment layout with flow sheets and P and IDs.
Escape routes, obstruction free.
Check all items on Master Equipment List and Layout Requirements List have been
included.
Piping and cabling included where required and no conflicts.
Compatibility with structural/civil drawings - no conflicts.
Pipe stress calculations where required.
Line sizing and numbering where required.
Space allowance for insulation of piping, if required.
No unnecessarily long pipe runs and unnecessary complexity, in general.
Review layout with respect to construction and tie-in philosophy.
Layout developed within existing site constraints.
Adequate provision for installation of future equipment (if any) and future tie-ins.
Conflicts with existing pipe work and cabling (above and below ground).
Conflicts with existing and revised hazardous areas.
Ensure there are no developments which may jeopardize granting planning permission.
Confirm any assumptions made about the existing plant operations capacity and function
is still valid.
Optimum use made of existing facilities, utilities buildings.
Compliance with the layout related Standards and Codes of Practice (to be completed
later).
Adequate pipe supports and cable trays.

3. CHECKLIST FOR MECHANICAL EQUIPMENT

3.1. General (Applicable to All Items)

Safety aspects including:

- integrity of design;
- guarding of couplings;
- protection of hot and moving parts;
- containment of rotor failure;
- noise and vibration;

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- isolation system and interlocks required.

Compliance with Specification and referenced documents.

Maintenance access and lifting arrangements.
System compatibility
Adequacy of monitoring arrangements and instrumentation.
Consider standardization with existing equipment.
Provision of documents.
Testing proposals.
Storage and Preservation requirements.

3.2. Pumps

Is the pump specification in line with schedule W4 and API 610.

Has right type of pump been selected?
Is the pump manufacturer on our AML (Approved Manufacturer List)
Check efficiency against specific speed.
Check the selected seal system (If the mechanical seal is a back to back type, the seal
pressure is often ca. P = Ps + ( Pd- Ps )/10 )
If there is an elbow in the suction line, the distance between the suction pump nozzle and
the elbow shall be minimal 8 times suction pipe diameter.
Check pump parameters (flow, pressure, sound level)
Check suction layout, ensure NPSHA is at least 1 meter greater than NPSHR.
Check delivery layout.
Check overall system for compatibility.
Liaison with pipework/electrical/instrument disciplines.
Protection instruments.
Control instruments.
Performance instruments.
Seals and seal arrangement.
Driver.
Materials selection/ NACE requirements.

Characteristics for stability, head rise and non overloading features.

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Base plate - balance between adequate stiffness and excess weight.

System for isolating valves need for minimum flow control.
Couplings.
Adequacy of test requirements.

3.3. Centrifugal Compressors

Is the centrifugal compressor specification in line with schedule D6 and API 617.
Has right type of compressor been selected?
Is the centrifugal compressor manufacturer on our AML (Approved Manufacturer List)
Rotor dynamic check;
- lateral critical speeds;
- torsional critical speeds;
- rotor response study.

Seal oil system.

Lub oil system.
Couplings.
Gearbox:
- thrust arrangements;
- pitch line velocity;
- single or double helical bearings;
- tooth materials/finish.

Performance instruments.
Monitoring instruments.
Materials/NACE requirements.
Case design.
Diaphragm construction.
Impellor construction and location on shaft.
Thrust bearing capacity and rotor axial balance.
Bearings.
Surge control system.
Heat exchangers.
Recycle connection.

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Supporting arrangements.
Rotor withdrawal.
System compatibility including blow down.
Head/flow characteristic:
- turndown;
- % pressure rise duty point to surge.

3.4. Gas Turbines

Is the Gas Turbine specification in line with DEP 31.29.70.31 (AFPC schedule to be
developed) and API 616.
Is the Gas Turbine manufacturer on our AML (Approved Manufacturer List)

Adequacy of combustion air filtration and anti-ice system.

Acoustique enclosure - ventilation/air changes/fans.
Gas generator change out arrangements.
Gas generator aerodynamics and cooling.
Power turbine aerodynamics and cooling.
Fuel acceptability.
Dual fuel and change over requirements.
Black start capability.
Fuel treatment system.
Starting arrangements.
Governing system and load sharing.
Turbine materials.
Bearings.
Couplings.
Torsional/lateral vibrations.
Lub. oil system.
Gearbox.
Bedplate.
Disposal of exhaust and waste gas streams.
Waste heat recovery aspects.
Compressor washing system.

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Control, protection, performance instrumentation.

Avoidance of wind-milling effect.

3.5. Instrument Air Compressors

Is the Instrument Air Compressors specification in line with schedule D2.

Has right type instrument/service compressor been selected?
Is the instrument/service compressor manufacturer on our AML (Approved Manufacturer
List)

Capacity of drier.
Efficiency of oil removal.
Safety aspects.
Sizing of driver.
Utility requirements and terminations.
Heat removal from enclosure.
Liaison with instrument/electrical disciplines.
Receivers and drainage.
Ensure machine unloaded at start-up.
Access for maintenance.
Single lift capability?

3.6. Heat Exchangers

Is the Heat Exchanger specification in line with schedule I (1,2,3) and TEMA standards.
Has right type Heat Exchanger been selected?
Is the Heat Exchanger manufacturer on our AML (Approved Manufacturer List)

Check thermal duty.

Check materials process side/utility side.
Orientation of nozzles.
Access - removal of bundle.
Pressure rating.
Construction details:

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- Locating of tubes;
- baffles;
- gaskets;
- channel;
- shell.

Relief valves/Bursting discs.

Liaison with process/materials.
Access to Fans/Louvres for Air Coolers.

3.7. Pressure Vessels

Does the design of the Vessel comply with schedule T and ASME 8 code or BS 5500.
Is the Vessel manufacturer ISO 9002 certified.

Materials selection.
Construction details.
Nozzles and orientation.
Internals.
Relief valves.
Review by process/materials Engineers.
Adequate instrument connections.

4. HVAC CONCEPTUAL DESIGN CHECK LIST

Continuous operation under normal conditions.

Prevention ingress of explosive gas into non-hazardous areas.
Heat removal to prevent high space temperatures.
Standby arrangements.
Access for preventative and routine maintenance.
System must not impair integrity of fire separation of the various areas.
Remote operation of plant and controls.

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Acceptable working conditions in enclosed hazardous areas, enclosed areas normally

unmanned and open areas normally manned.
Positive pressurization of non-hazard areas with respect to hazard areas.
Dilution and removal of hazardous areas.
Control of ventilation in emergency in accordance with shutdown logic.
Provision of ventilation air supplies to personnel and essential service equipment during
emergency.
Operation during hookup.
Fresh air to be drawn from safe areas.
Duplicate fans, 100% spare, auto changeover for all areas.
Check system designed to correct ambient conditions including margins/contingencies:
- wind speed;
- relative humidity;
- air temperatures.

Air intake and discharge for same system located on same face or in zones of equal wind
pressure.
Protection of intake and discharge points from wind driven rain and snow.
Standardisation of components.
Suitability of electrical equipment for area classification.
Full commissions of modular HVAC system prior to installation at permanent location.
Check system meets required internal temperature, pressurization and air change
requirements of enclosed areas.
Noise levels.
Separate HVAC systems for hazardous/non-hazardous areas and per module.
Supply extract system penetrating external walls - fitted dampers.
Gas detectors at extract ducts and fresh air intakes.
Air distribution self-balancing to within 80%.
Air filters at all air intakes.
Non-hazardous areas - fan capacity 50% excess.
Heating where required.
Automatic temperature control in areas containing electronics/telecomms.
Airlock doors where required.
Spacing for humidifiers.
Fire/gas dampers at A0/A60 penetrations.
Remote control from ICC.

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Supply ducting to other areas, not through galley.

Check compliance with shutdown diagrams.
Inlet/outlet duct separation.
Access doors of adequate size.
Lub points accessible.
Access for washable screens.
Access for belt condition.
Access for birdguards.
Fresh air intakes relative to:
- exhausts from fuel burning equipment;
- extract outlets and discharge from HVAC systems;
- lub oil vents, drain vents and process relief;
- area classification zone lines;
- flares.

Supplies required from central utilities.

Physical obstructions to HVAC intake and discharge openings.
Has it been demonstrated that natural ventilation is adequate?
Evaluation of air flow pattern within modules and effects of wind on the HVAC systems.
Adjustable ventilation rates where required.
Adequacy of weather shielding in open areas.
Check area classification against plant operating requirements.

5. MAINTENANCE CHECKLISTS

Access Requirements
In situ Inspection
Can equipment be easily reached for visual inspection or for NDT?
In situ Repair/Maintenance
Is layout arranged so that any item can be reached, preferably without the use of
scaffolding?
Has sufficient withdrawal/local lay-down area been provided for maintenance?
Has sufficient thought gone into, with regard to safe routes to workshop, etc?

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- control access routes;

Has sufficient lifting equipment/points being supplied for local repairs, e.g. pad eyes,
beams, etc.
Ensure adequate facilities exist for handling and lifting.
Have sufficient isolation facilities been provided for in situ repair/maintenance without
affecting main equipment?
An example would be back-up instrumentation, e.g. level gauges, pressure gauges which
could be overhauled locally or removed for repair without shutting down main equipment,
i.e. no/min. facility deferment.

Has sufficient isolation been provided to allow safe in situ repair or removal to workshop?
Does this means of isolation ensure parallel operation of like equipment whilst repair is
taking place?

Is there sufficient redundancy?

Has sufficient isolation been provided to allow major inspection/maintenance to be

carried out with:
- safety in mind?
- the effects on other operating systems?

5.1 Maintenance Execution

Is local environment conducive to a high standard of repair/maintenance? e.g.:

- noise;
- atmospheric conditions;
- lighting.

During repairs/maintenance in a hazardous area is there local communication between

work area and central control room under both normal and emergency conditions?
Is there local control/monitors to allow efficient re-commissioning of plant on completion
of task.
Is the equipment designed such that components can be removed easily without removal
of a large number of other components?
Do maintainers require protective clothing or equipment due to thermal, toxicological,
radiological, unusual or other hazards?

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Is the equipment design in its simplest form conducive with functional and service
conditions? Simple design can mean repair/maintenance carried out by personnel with
minimum training.
Has a modular replacement policy been adopted to allow the replacement of small
assemblies by modular packages?

5.2 Special Tools

Are special tools required for:

- normal operating maintenance;
- calibration;
- minor overhauls;
- major overhauls;
Are these special tools to be purchased:
- with main package by the Project?
- separately by operator's Maintenance Department?

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