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1、MANUAL FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT DEP 61.10.08.11-Gen. July 1999 DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell Internat
2、ional Oil Products B.V. and Shell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmit
3、ted in any form or by any PDF created with pdfFactory Pro trial version means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners. PDF created with pdfFactory Pro trial version PREFACE DEP (Design and Engineering Practice) public
4、ations reflect the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience
5、 acquired during their involvementwith the design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standard
6、s and codes of practice. The objective is to set the recommendedstandard for good design and engineeringpractice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximu
7、m technical and economic benefit from standardization. The information set forth in these publications is provided to users 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 s
8、ystem of DEPs is expected to be sufficiently flexible to allow individual operating companies 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 the quality of work and the at
9、tainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contrac
10、tor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companie
11、s receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respe
12、cts to the terms and conditions of the relevant Service Agreement. 2)Other parties who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tende
13、rs for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for
14、 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. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or a
15、ny company affiliated to these companies that may issue DEPs 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 SIOP and SIEP, be disclosed by users to any com
16、pany 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 SIOP and SIEP. The copyright of DEPs vest
17、s in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP 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 SIOP. NOTE: In a
18、ddition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are als
19、o applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 61.10.08.11-Gen. July 1999 Page 2 PDF created with pdfFactory Pro trial version TABLE OF CONTENTS 1.INTRODUCTION .5 1.1SCOPE 5 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONS
20、IDERATIONS5 1.3DEFINITIONS 5 1.4CROSS REFERENCES.6 1.5SUMMARY OF CHANGES SINCE LAST REVISION 6 2.INSPECTION .7 2.1GENERAL7 2.2ROGUE MATERIALS 7 2.3DESIGN MODIFICATIONS .8 3.PRESSURE TEST PROCEDURES.9 3.1GENERAL9 3.2HYDROSTATIC TESTING.9 3.3PNEUMATIC TESTING .11 4.MECHANICAL EQUIPMENT, GENERAL .12 5.
21、VESSELS, COLUMNS, REACTORS AND THEIR INTERNALS 13 6.FURNACES.14 7.BOILERS.16 8.DESUPERHEATERS - STEAM TEMPERATURE CONTROL EQUIPMENT 17 9.SHELL-AND-TUBE HEAT EXCHANGERS 18 10.AIR-COOLED HEAT EXCHANGERS .19 11.GRAPHITE EQUIPMENT 20 12.ATMOSPHERIC STORAGE TANKS 21 13.ATMOSPHERIC TANKS FOR SOLIDS AND SI
22、LOS 22 14.PIPING 23 15.VALVES 25 16.SAFETY/RELIEF VALVES26 17.RUBBER AND GRE/GRP-LINED EQUIPMENT .27 18.ROTATING EQUIPMENT 28 19.CENTRIFUGAL COMPRESSORS 30 20.RECIPROCATING COMPRESSORS/VACUUM PUMPS . 33 21.ROTARY TYPE COMPRESSORS 35 22.BLOWERS/FANS 37 23.CENTRIFUGAL PUMPS .38 24.RECIPROCATING PUMPS
23、.39 25.ROTARY POSITIVE-DISPLACEMENT PUMPS . 41 26.MIXERS .42 27.ROTARY FILTERS45 28.ROTATING DISC CONTACTORS 47 DEP 61.10.08.11-Gen. July 1999 Page 3 PDF created with pdfFactory Pro trial version 29.STEAM TURBINES.48 30.GAS TURBINES50 31.DIESEL ENGINES.52 32.ROTARY STOP VALVES53 33.EXTRUDERS.54 34.
24、REFERENCES 55 APPENDICES APPENDIX 1RULES FOR EXPANDING FURNACE TUBES INTO RETURN FITTINGS 56 DEP 61.10.08.11-Gen. July 1999 Page 4 PDF created with pdfFactory Pro trial version 1.INTRODUCTION 1.1SCOPE This DEP specifies requirements and gives recommendations for field inspection prior to commission
25、ing of mechanical equipment (e.g. during new construction projects and minor projects, and existing equipment following maintenance or plant modifications). This DEP is a revision of the DEP with the same number dated November 1992. Other than editorial changes, this revision has not been extensive;
26、 a summary of the main non-editorial changes is given in (1.5). The information given in this DEP has been arranged according to the type of equipment, such as columns, furnaces, compressors, pumps etc., and a separate section is dedicated to pressure testing procedures. Excluded from the scope of t
27、his DEP is the inspection of the instrumentation associated with the mechanical equipment. Inspection of equipment can be divided into three main stages, only the second of which is within the scope of this DEP: 1) Manufacturing-whichshould be coveredby theappropriatespecifications, standards and co
28、des laid down in the equipment purchase order. 2) Erection and precommissioning 3) Operational maintenance -which should be coveredby local procedures at the operating site. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIOP and SIEP, the distribution of
29、this document is confined to companies forming part of or managed by the Royal Dutch/Shell Group, and to Contractorsnominatedbythem(i.e.thedistributioncodeis“C“,asdefinedin DEP 00.00.05.05-Gen.). This DEP is intended for use in oil refineries, chemical plants, gas plants, supply/marketing installati
30、ons and, where applicable, in exploration and production. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of
31、requirements will be acceptable as regards safety, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this document which is considered to be necessary in order to comply with national and/or local regulations. The Principal m
32、ay then negotiate with the Authorities concerned with the object of obtaining agreement to follow this document as closely as possible. 1.3DEFINITIONS For the purposes of this DEP the following definitions shall apply: 1.3.1General definitions The Contractor is the party which carries out all or par
33、t of the design, engineering, procurement, installation, and commissioning or management of a project or operation of a facility. The Principal may sometimes undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and ser
34、vices to perform the duties specified by the Contractor. DEP 61.10.08.11-Gen. July 1999 Page 5 PDF created with pdfFactory Pro trial version The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical
35、 requirements. The Principal may also include an agent or consultant, authorised to act for the Principal. The word shall indicates a requirement. The word should indicates a recommendation. 1.4CROSS REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number
36、 is shown in brackets. Other documents referenced by this DEP are listed in (34). 1.5SUMMARY OF CHANGES SINCE LAST REVISION Other than editorial changes, the following are the main changes since the last revision: SectionChange 3.1Added reference to DEP 31.40.40.38-Gen. 3.2“Potable water” redefined
37、6Deleted items 6 and 8; minor changes elsewhere 7Deleted items 6, 12 and 13 8Deleted item 7 14 (item 20)Pressure testing is now permitted on fully painted piping spools (including welds) under certain conditions 16Revised item 1; added new items 8, 9 and 10 26Completely revised 27Added new item 37 3
38、1Revised item 9 DEP 61.10.08.11-Gen. July 1999 Page 6 PDF created with pdfFactory Pro trial version 2.INSPECTION 2.1GENERAL Handover procedures shall be agreed between the Principal and the Contractor before precommissioning commences, and shall include the respective responsibilities of the Contra
39、ctor, Manufacturer and the Principal. Early inspection of individual items will allow any non-compliances to be identified at an early stage, thus avoiding subsequent delays in construction progress. Furthermore, special attention to precommissioning inspection will contribute to equipment reliabili
40、ty when the equipment is brought on stream. As it will not normally be possible to complete all checks on any one item at the same time, checklists should be used to ensure that essential points are not overlooked. Systematic performance of the handover inspections will facilitate the collection of
41、accurate as-built information and baseline measurements essential for completion of the Equipment Record Cards, see DEP 70.10.01.10-Gen. The objective of inspection during construction or maintenance is to ensure that: 1.the equipment has been supplied in accordance with the purchase order; 2.the eq
42、uipment has been installed correctly; 3.all required documentation has been completed. A piece of equipment or part of an installation which is meant to operate with other equipment shall be inspected and tested in conjunction with the latter to ensure proper operation of the complete assembly, for
43、example, a compressor together with its drive, auxiliary gear and piping system. A record of all manufacturing data books, shop inspection reports, and Manufacturers inspection and test reports should be kept in the equipment file. This information shall be recorded on the appropriate Equipment Reco
44、rd Card, which shall be completed before commissioning. All pressure testing, when performed by a Contractor, shall be witnessed by the Principal and shall be recorded on the appropriate Equipment Record Card. 2.2ROGUE MATERIALS A rogue material is a material of incorrect type or grade. Many materia
45、ls are similar in appearance and so the installation of rogue materials can easily occur. In order to eliminate rogue materials from equipment or an installation, explicit procedural checks shall be established for critical circuits. Critical circuits are selected according to process flow schemes,
46、inspection data and inspection experience. The criteria for selection shall be: -service conditions (high temperature, low temperature, high pressure); -nature of products (corrosive, flammable,lethal); -type of material (alloys and alloy steels, carbon steel with special requirements). For these cr
47、itical circuits the minimum special inspection requirements shall apply: 1.Full traceability of all materials used, i.e transfer and recording of heat numbers or other unique identifiers. 2.Random alloy verification prior to installation (only for alloys and alloy steels such as 5 Cr- 1/2Mo steel).
48、3.A 100% alloy verification check, including all weldments, after completion of erection of DEP 61.10.08.11-Gen. July 1999 Page 7 PDF created with pdfFactory Pro trial version these systems (only for alloys and alloy steels such as 5 Cr- 1/2Mo steel). 2.3DESIGN MODIFICATIONS Design modifications du
49、ring the manufacturing period may not be incorporated in the plant equipment after the final inspection in the shop. An up to date record shall be kept of all design modifications and associated specifications and drawings. The plant equipment shall be examined on arrival at site for compliance with purchase order requirements and any non-conformity reported and recorded. If the plant equipment requires modification on site it is essential that fu