AIR PRODUCTS AND CHEMICALS, INC.

GAS VIII – Enhancement Project

30% 3D Model Review Terms of Reference

Document Number: Release Purpose: For Project Rev: 00

TABLE OF CONTENTS

1.0 PURPOSE .................................................................................................................... 3

2.0 SCOPE......................................................................................................................... 3
2.1 General ........................................................................................................................ 3
2.2 Safety, Operational and Maintenance Aspects ............................................................. 3
3.0 APPROACH ................................................................................................................. 4
4.0 HANDLING OF COMMENTS ....................................................................................... 4
5.0 MEETING OUTPUT & CLOSURE ................................................................................ 4
6.0 FURTHER REVIEWS ................................................................................................... 5
APPENDIX 1 .............................................................................................................................. 6

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 Document Number: Release Purpose: For Project Rev: 00

1.0 PURPOSE
In the course of conceptual engineering a 3D block model has been developed. The block
model has been used to establish the location of main equipment and main pipe routings.

The model provides a visual check on safety, operability and maintainability and facilitates
the engineering and erection of the units. 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.

The Focus of the 30 % 3D model review is on the following key areas of safety,
accessibility, layout, ergonomics, and construction. It is not design to be a detailed
constructability review. This will be completed later in the engineering design phase.

It is suggested that the following disciplines are represented in the review team;

− Process technology;
− Operations;
− Maintenance;
− Plant lay-out and piping;
− Technical safety and operability;
− Projects;

2.0 SCOPE
2.1 General
The model shall be checked against the latest issue of the PFDs and plot layout drawings.
The review team should ensure that when a modification is proposed it suits its purpose,
and does not conflict with other requirements. In addition they should also consider it is
practical, safe, in accordance with the PFDs and also economic. If in doubt, consult the
appropriate specialists of other disciplines.

The checklist in Appendix I should be used during the model review. It should be noted
that the checklist is not exhaustive and shall not overrule sound judgement.

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 % and 60 % complete.

2.2 Safety, Operational and Maintenance Aspects

The 3D-CAD system shall be structured in such a way that all disciplines involved can
check whether sound design and engineering criteria have been met with respect to
safety, operability and maintenance and facilitate the engineering and erection of the
plant. This shall include accessibility for maintenance and fire fighting, location of valves,
constructability, process instrumentation, routing of the piping adequate for the process,
location of emergency shut-down stations, proper and safe location of vents and drains,
location of fire protection and fire-fighting equipment and escape routes.

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Document Number: Release Purpose: For Project Rev: 00

3.0 APPROACH
A review will be completed based on the output from the Piping & Layout 3D model. This
review will be presented in the form of 3D Model Snapshots, fly through video and 2D plot
plan and elevation drawings. The review team shall use the check list included within
appendix 1 as a basis for the model review.

The items listed below should be included in the 30 % model review, plus any other items
which are applicable for the particular project.

- Location and orientation of all equipment and all space consumers (including future
extensions);
- Structures (steel and concrete inclusive fire proofing);
- Plot determining piping / ducts;
- Main access ways / operational access;
- Major piping that influences equipment positions;
- Concrete slabs, paving and roads;
- Packaged unit location and orientation;
- Escape routes (on grade and elevation);
- Pipe racks and main pipe support structures;
- Outline of underground electrical and instrumentation trenches;
- Main electrical and instrumentation cable trays / racks;
- Underground sewer systems and collecting and separation systems drainage / sewage;
- Buildings in outline, e.g. control room, analyser houses, switch rooms;
- Dropout/bundle pulling areas;
- Laydown areas;
- Mobile crane aprons

4.0 HANDLING OF COMMENTS

Any necessary changes shall be agreed upon and recorded in the MOM and shall be
marked with reference numbers to avoid misunderstanding.

After every review (30, 60%), the team shall decide if the level of completion of the model
is in line with the requirements defined in (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.

5.0 MEETING OUTPUT & CLOSURE

The 30 % model review shall be concluded with a statement describing which aspects are
frozen at this stage.

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Document Number: Release Purpose: For Project Rev: 00

6.0 FURTHER REVIEWS

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 PFDs. The 60 %
model review shall be concluded with a statement describing which aspects are frozen at
this stage.

The items listed below should be included in the 60 % model review, plus any other items
which are applicable for the particular project.

- The actions resulting from the 30 % model review;

- Location of spading points;
- All other piping largely completed;
- Ladders, stairs and platforms;
- Platforms for valves and equipment and operation;
- Permanent cranes and hoisting beams (based on lifting study);
- Final dimensions of table tops, structures and steel constructions;
- Secondary steelworks and bracing;
- Eye bath and safety shower locations;
- Pipe supports locations and types;
- Local operation panels;
- Fire fighting systems (hydrants, monitors, water spray systems, etc;);
- Instrument transmitters and outlines of junction boxes, secure instrument air vessels;
panels and cabinets inclusive stands, safety critical sensors / switches;
- Electrical equipment such a outdoor panels, major lighting towers;
- Above-ground instrumentation and electrical tray routing.
- Utility stations;

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Document Number: Release Purpose: For Project Rev: 00

APPENDIX 1

CHECK LISTS

1.0 PIPING

Item Check Point Comment

1.1 Are valves, spading positions, flushing and draining and
instrument connections properly located, in relation to
normal operations as well as shutdowns? Take special
care of manifolds relief valves and large control valves.
1.2 If spades have been provided, is there sufficient storage
area when the spacers are installed?
1.3 If spectacle blinds are fitted, are they accessible and can
they be turned safely? Consider additional or adapted
platforms where applicable.
1.4 Has the number of flanges been minimised?
1.5 Check the elevation of piping and its clearance to
walkways and maintenance equipment (e.g. lifting
equipment). Avoid head bumpers.
1.6 Are start-up and circulation pipes short? Have dead ends
been avoided? Can the system be flushed and drained?
1.7 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.
1.8 Are long small diameter pipes (e.g. instrument impulse
pipes) supported properly to prevent breakage due to
vibration?
1.9 Check for adequate space and jacking facilities to
remove man-hole covers, especially for those with
inserts.
1.10 Have dead end sections been avoided. Has piping been
designed for ease of drainage and/or venting?
1.11 Is piping with instrument connections positioned such that
these connections are easily accessible?
1.12 Is the measurement point in the correct process location?
Have the necessary platforms and walkways been
provided?
1.13 Is there adequate straight length upstream and
downstream of a flow meter or orifice flange.
1.14 Have special provisions for commissioning and initial
start-up been properly addressed? (e.g. temporary large
blow spools and silencers).
1.15 Has cold, large and critical piping been checked for
thermal movement?

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Document Number: Release Purpose: For Project Rev: 00

2.0 VALVES

Item Check Point Comment

2.1 Have valves in pipe crossovers been avoided as much as
possible?
2.2 Check that there are no valves installed with the stem
pointing downward.
2.3 Are hand wheels easily accessible for operation and not
obstructing walkways or platforms? (Consider the stems,
especially when in the open position.)
2.4 Are valves for emergency operations operable from
grade level? Are valves that need frequent attention
easily accessible?
2.5 Check that control valve assemblies are located at
ground level or on platforms, except when otherwise
required for process reasons.
2.6 Has installation of valves outside of platforms been
avoided?
2.7 Have spring-loaded and/or extra block valves been used
where valves may freeze up when draining or sampling?

3.0 RELIEF AND VENT SYSTEMS

Item Check Point Comment

3.1 Check that inlet pipes to relief valves are self-draining
into process equipment
3.2 Check the accessibility of relief valves sets for
maintenance and inspection. All relief valves should be
accessible for removal (by hoisting equipment if
necessary).
3.3 Check relief valves & vents discharging to atmosphere to
a safe location and direction.
3.4 Check relief valve outlet pipe arrangements such that
supports can be provided to cope with reaction forces.

4.0 ENVIRONMENTAL CHECKS

Item Check Point Comment

4.1 Check if any process liquid drained from equipment can
be handled in an environmentally acceptable manner, in
line with general approach of closed loops for liquid
draining or vents.
4.2 Check suitable location of vents / drains from instruments
in analyser house.

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