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Abu Dhabi Oil Refining Company

GENERAL EQUIPMENT REQUIREMENTS DGS-MU-001


Rev- 2 Oct 2011

DGS-MU-001 Rev-2

GENERAL EQUIPMENT REQUIREMENTS

Amendment History

02 Oct 2011 AMD-MU-001-002, Rev.2 Clause #: 3.0 RR / SM SMK / SOD Oct 2011
/ MLM

01 May 2009 AMD-MU-001-BECHTEL Clause #: SMK / QAM / MAY May 2009


2.0,4.0,6.0,7.0,10.0,11.0,14.5 MLM /HD

No Date Amendment Description Proposed Approved Incorporated

DGS History

2 Oct 2011 DGS-MU-001 Rev-2 AMD-MU-001-002, Rev.2 RR / SM / SMK / SOD


MLM

1 May 2009 DGS-MU-001 Rev-1 AMD-MU-001-BECHTEL SMK / MLM / QAM / MAY


HD

0 Mar 2006 DGS-MU-001 Rev-0 Previous Project SMK /MLM / ETSDM /


HD EPDM

No Date Description Source Reviewed Approved

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GENERAL EQUIPMENT REQUIREMENTS DGS-MU-001


Rev- 2 Oct 2011

TABLE OF CONTENTS

1.0 GENERAL ......................................................................................................................... 4


1.1 INTRODUCTION...................................................................................................... 4
1.2 PURPOSE................................................................................................................ 4
1.3 DEFINITIONS .......................................................................................................... 4
1.4 EXCLUSIONS .......................................................................................................... 4
2.0 CODES AND STANDARDS .............................................................................................. 4
3.0 REFERENCE DOCUMENTS ............................................................................................ 5
4.0 DOCUMENT PRECEDENCE ............................................................................................ 6
5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ............................................... 6
6.0 QUALITY ASSURANCE/QUALITY CONTROL ................................................................. 6
7.0 DOCUMENTATION ........................................................................................................... 7
8.0 SUBCONTRACTORS/SUBVENDORS ............................................................................. 7
9.0 HANDLING ........................................................................................................................ 8
10.0 DESIGN............................................................................................................................. 8
11.0 MATERIALS ...................................................................................................................... 9
12.0 FABRICATION................................................................................................................... 9
12.1 WELDING ................................................................................................................ 9
12.2 PAINTING................................................................................................................. 9
13.0 INSPECTION AND TESTING.......................................................................................... 10
13.1 INSPECTION ......................................................................................................... 10
13.2 TESTING................................................................................................................ 10
14.0 ADDITIONAL REQUIREMENTS ......................................................................................11
14.1 NOISE .....................................................................................................................11
14.2 PERFORMANCE ................................................................................................... 12
14.3 IDENTIFICATION AND TAGGING ......................................................................... 12
14.4 SPARE PARTS....................................................................................................... 13
14.4 LUBRICATION ....................................................................................................... 13
14.5 SPECIAL TOOLS PROVIDED BY VENDOR ......................................................... 13
ADDENDUM SHEET ................................................................................................................ 14

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GENERAL EQUIPMENT REQUIREMENTS DGS-MU-001


Rev- 2 Oct 2011

List of Authorized Signatures / Initials

DGS Discipline Committee Member, ADRD: Ramesh Rao (RR)

DGS Discipline Committee Member, RRD: Somen Mukherjee (SM)

DGS Discipline Committee Member, E&TSD: Megharaj L. Mane (MLM)

DGS Discipline Committee Member Leader, E&TSD: Shivaji M Karade (SMK)

Mechanical Engineering Department Manager, E&TSD: Shivaji M Karade (SMK)

Engineering & Technical Support Division Manager: Salem Obaid Al Dhaheri (SOD)

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1.0 GENERAL

1.1 INTRODUCTION

This specification contains the general requirements for Speciality Process and Material
Handling Equipment for use in the COMPANY'S Project. Refer to the individual
Equipment Data Sheets for specific operating conditions and duty requirements.

This specification is intended for use in the design and fabrication of the equipment for
the Project.

1.2 PURPOSE

This specification shall be used in conjunction with the individual Equipment Data
Sheets. This specification supplements the requirements specified on the individual
Equipment Data Sheets. Where conflicts exist, the Data Sheet shall govern.

1.3 DEFINITIONS

For the purposes of this specification, the following definitions shall apply:

CONCESSION REQUEST - A deviation requested by the SUBCONTRACTOR or


VENDOR, usually after receiving the contract package or purchase order. Often, it
refers to an authorization to use, repair, recondition, reclaim, or release materials,
components or equipment already in progress or completely manufactured but which
does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is
subject to COMPANY approval.

SHALL - Indicates a mandatory requirement.

SHOULD Denotes an action or requirement which is not mandatory but which is


strongly recommended.

1.4 EXCLUSIONS

See individual Equipment Data Sheets.

2.0 CODES AND STANDARDS

It shall be the VENDORS responsibility to be, or to become, knowledgeable of the


requirements of the referenced Codes and Standards.

The following codes and standards, to the extent specified herein, form a part of this
specification. The edition in force at the time of CONTRACTORs/ VENDORs proposal
shall apply.

American Society of Mechanical Engineers (ASME)

ASME B31.3 Process Piping

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American Welding Society (AWS)

AWS-A2.4 Standard Symbols for Welding, Brazing and Non destructive


Examination

AWS-A3.0 Standard Welding Terms and Definitions

AWS-D1.1 Structural Welding Code for Steel

European Committee for Standardization (EN)

EN 10204 Types of Inspection Documents - Metallic Products

International Organization for Standardization (ISO)

ISO 9001 - 2000 Quality Management System Requirements

ISO 9004 - 2000 Quality Management Guidelines for Performance Improvement


System

ISO 19011 Guidelines for Quality and/or Environmental System Auditing

See individual Equipment Specifications / Data Sheets for additional Codes and
Standards.

3.0 REFERENCE DOCUMENTS

The following reference documents, to the extent specified herein, form a part of this
specification.

PROJECT Specifications:

DGS-CU-002 Structural Engineering Design Criteria

DGS-MD-007 Requirements For Manufacturing Data Report For Pressure


Vessels

DGS-MU-002 Preservation and Export Packing

DGS-MU-003 Spare Parts

DGS-MU-004 Lubrication Requirements

DGS-MU-009 Equipment Noise Control

DGS-MU-012 Requirements for Manufacturing Data Report For Non-pressure


Vessel Equipment

DGS-MU-013 Criticality Rating System

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DGS-MU-014 Minimum Shop Inspection and Certification Requirements

DGS-MX-001 Painting

Health, Safety and Environmental (HSE):

ADNOC-COPV6-01 Identification and Integrity Assurance of HSE Critical Equipment


and Systems

HSE-CP20 HSE Critical Equipment & Systems

4.0 DOCUMENT PRECEDENCE

It shall be the Subcontractor/Vendors responsibility to be or to become knowledgeable


of the requirements of the referenced Codes and Standards.

The Subcontractor/Vendor shall bring to Contractors attention any apparent conflict


between this specification, the related data sheets, the Codes and Standards and any
other specifications mentioned herein. Resolution and/or interpretation precedence
shall be obtained from the CONTRACTOR in writing before proceeding with the design/
manufacture.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or other
PROJECT documents as applicable.

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to this specification and its attachments shall be sought by the
VENDOR only through CONCESSION REQUEST format. CONCESSION REQUESTS
require CONTRACTOR'S and COMPANY'S review/approval, prior to the proposed
technical changes being implemented. Technical changes implemented prior to
approval are subject to rejection.

6.0 QUALITY ASSURANCE/QUALITY CONTROL

VENDORS proposed quality system shall fully satisfy all the elements of ISO 9001 -
2000 and ISO 9004 2000 with due regard to ISO19011. The quality system shall
provide for the planned and systematic control of all quality-related activities performed
during design, development, production, installation or servicing (as appropriate to the
given system).

Implementation of the system shall be in accordance with the CONTRACTORS Quality


Manual and Project Specific Quality Plan, which shall both together with all
related/referenced procedures, be submitted to COMPANY for review, comment and
approval as required by purchase/contract documents.

The Criticality Rating (CR) System outlined in Project Specification DGS-MU-013 shall
be used by CONTRACTOR or CONTRACTOR'S designee to develop the design

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checking levels and minimum requirements for shop inspection, testing and material
certification given in Project Specification DGS-MU-014.

7.0 DOCUMENTATION

VENDOR shall submit the type and quantity of drawings and documentation for
CONTRACTORs authorization or information as listed in the individual Material
Requisitions and Purchase Orders.

Mutual agreement on scheduled submittal of drawings and engineering data shall be an


integral part of any formal Purchase Order.

Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR or


SUBVENDORS of any responsibility in meeting the requirements of the specifications.
Such comments shall not be construed as permission to deviate from requirements of
the Purchase Order unless specific and mutual agreement is reached and confirmed in
writing.

Each drawing shall be provided with a title block in the bottom right-hand corner
incorporating the following information:

Official trade name of the Manufacturer/Vendor

Companys Name/Plant Site and Unit

VENDOR'S drawing number.

Drawing title giving the description of contents whereby the drawing can be
identified.

A symbol or letter indicating the latest issue or revision.

PO number and item tag numbers.

Revisions to drawings shall be identified with symbols adjacent to the alterations, a brief
description in tabular form of each revision shall be given, and if applicable, the authority
and date of the revision shall be listed. The term :Latest Revision shall not be used.

VENDOR shall submit Manufacturers Data Book in accordance with Specification DGS-
MD-007 for pressure vessels and/or Specification DGS-MU-012 for all other Equipment.

8.0 SUBCONTRACTORS/SUBVENDORS

The VENDOR shall assume unit responsibility and overall guarantee for the equipment
package and associated equipment.

The VENDOR shall transmit all relevant purchase order documents including
specifications to his SUBVENDORS and SUBCONTRACTORS.

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It is the VENDOR'S responsibility to enforce all Purchase Order and Specification


requirements on his SUBVENDORS and SUBCONTRACTORS.

The VENDOR shall submit all relevant SUBVENDOR and SUBCONTRACTOR drawings
and engineering data to the CONTRACTOR.

The VENDOR shall obtain and transmit all SUBVENDOR and SUBCONTRACTORS
warranties to the CONTRACTOR/COMPANY, in addition to the system warranty.

9.0 HANDLING

Preparation for shipment shall be in accordance with the VENDOR'S standards and as
noted herein. VENDOR shall be solely responsible for the adequacy of the preparation
for shipment provisions with respect to materials and application, and to provide
equipment at the destination in ex-works condition when handled by commercial
carriers.

Adequate protection shall be provided to prevent mechanical damage and atmospheric


corrosion in transit and at the jobsite.

Preparation for shipment and packing will be subject to inspection and rejection by
COMPANY'S/CONTRACTOR'S inspectors. All costs associated with such rejection
shall be to the account of the VENDOR.

After inspection and test, equipment shall be completely free of water and dry before
start of preparation for shipment.

All equipment and material shall be preserved and export packed in accordance with
Project Preservation and Export Packing Specification, DGS-MU-002.

10.0 DESIGN

The equipment shall be designed in accordance with the individual Equipment Data
Sheet.

Requirements for live loads, earthquake load, wind load shall be in accordance with
Project Specification DGS-CU-002.

The equipment shall be designed for a minimum service life of 30 years and 5 years
uninterrupted operation.

Equipment selection shall be based on the approved VENDORS list for the PROJECT
and according to the applicable standards. The equipment shall be designed and
selected considering the local environment to reflect the optimum maintenance policy
consistent with safe and efficient operation. Where the equipment needs to be designed
on sound Engineering judgment different from that mentioned above, COMPANY
approval for variance shall be sought.

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Due consideration shall be given for field proven latest state-of-the art technology and
features for the equipment. In such cases, adequate backup documentation shall be
provided by the proposed VENDOR furnishing sufficient and satisfying evidence that the
updated ones are widely used for a length of time in similar and comparable industrial
environment.

Long term maintainability and life cycle analysis for any major equipment, to optimize
maintenance, costs shall be considered in the selection.

11.0 MATERIALS

VENDOR shall furnish Material Certificates in accordance with the requirements of


EN 10204 (formerly DIN 50049). The type of certificate required 2.1, 2.2, 3.1 OR
3.2 is determined by the inspection class assigned to the type of equipment or material.
Component parts of a piece of equipment may require different types of certificates. For
certification requirements, refer to Project Specification DGS-MU-014.

Carbon content of carbon and carbon-manganese steels shall not exceed 0.23%, except
for forgings and castings, where this may be relaxed to 0.25%. For pressure containing
components, the carbon equivalent (CE) shall not exceed 0.43, as given by:

Mn Cr + Mo + V Cu + Ni
CE =C + + +
6 5 15

Equipment bolting shall be coated, as applicable, in accordance with Project


Specification DGS-MX-001.

Asbestos or asbestos filled materials shall not be used for any component. Refer to
individual Equipment Data Sheets for additional material requirements.

12.0 FABRICATION

12.1 WELDING

Welding symbols shall be in accordance with American Welding Society (AWS) A2.4.

Welding terms and definitions shall be in accordance with American Welding Society
(AWS) A3.0.

All structural welding shall conform to the requirements of American Welding Society
(AWS) D1.1.

See individual Equipment Data Sheets for additional welding requirements.

12.2 PAINTING

Surface preparation and painting shall be in accordance with Project Painting


Specification DGS-MX-001.

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13.0 INSPECTION AND TESTING

13.1 INSPECTION

Materials and workmanship shall be subject to inspection by COMPANY/


CONTRACTOR in the shop and in the field.

COMPANY/CONTRACTORS Inspector will check, as a minimum, the following:

Equipment components metallurgy


Dimensions
Connection sizes and locations
Quality of workmanship against certified drawings
Data
PO documents

COMPANY/CONTRACTOR or a representative reserves the right to visit or be in


residence at MANUFACTURER/VENDORS shops to ensure that established schedules
are being met and to ensure that quality control is being maintained at an acceptable
level.

13.2 TESTING

13.2.1 All equipment, such as pressure vessels and exchangers, shall be hydrostatically tested
in accordance with Project equipment specifications.

13.2.2 All packaged unit piping shall be pressure tested in accordance with ASME B31.3 and
as follows:

a. The chloride content in the water used for the hydrostatic testing of piping
manufactured from or containing parts manufactured from austenitic stainless steel
(e.g. 18 Cr-8 Ni or 18 Cr-10 Ni-2 Mo) shall be controlled as indicated below.

The concentration of the chlorides by evaporation of hydrotest water


remaining in the piping system may cause stress corrosion cracking of the
piping near welds. Provisions must be made to ensure that hydrotest water is
fully drained and/or flushed from the piping system. The water used for the
hydrostatic test, apart from the requirements as to chloride content, shall be
free from sediment or undissolved solids of any type.

If the piping metal temperature exceeds 50C during commissioning,


operation or nonoperation, and the piping is flushed with condensate or
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demineralized water immediately after testing AND the water can be fully
drained and completely removed immediately after testing (e.g. by mopping
up), hydrotest water containing up to 200 mg/kg chlorides may be used for the
pressure test. It is essential when flushing with condensate or demineralized
water to ensure that all surfaces previously wetted during the pressure test are
flushed.

If the piping metal temperature exceeds 50C during commissioning,


operation or nonoperation, AND proper drainage is not possible (i.e. low
points in VENDOR piping that was not provided with a drain), the
recommended practice is to utilize water containing less than 1 mg/kg
chlorides, i.e. condensate or demineralized water.

No attempt should be made to remove remnants of water by blowing with hot


air or other gas, unless the system has been hydrostatically tested with, or
properly flushed with, condensate or demineralized water.

A suitable filter shall be provided in the hydrotest water fill line to remove sand,
rust, and other particles in the test water. VENDOR shall submit filter
requirements, as part of the hydrotest procedure, to the COMPANY/
CONTRACTOR for approval.

13.2.3 Instruments and controls shall be checked for continuity and operation at the factory.

13.2.4 Following field assembly, all control and safety devices shall be tested for compliance
with this specification and with local codes and regulations.

13.2.5 After any inspection or test, COMPANY/CONTRACTOR may reject the equipment or
any component thereof for any defect or nonconformance to the specifications. Notice
of rejections shall be conveyed in writing and shall state the details in which the
equipment is defective or not in conformance to the specifications.

13.2.6 MANUFACTURER/VENDOR shall promptly correct the defects and ensure that the
equipment complies with the specifications. Thereafter, if COMPANY/ CONTRACTOR
so requires, the test shall be repeated at MANUFACTURER/ VENDORS cost, as many
time as required to meet the performance guarantee.

13.2.7 MANUFACTURER/VENDOR shall not ship any equipment or any parts thereof from
MANUFACTURER/VENDORS premises, until COMPANY/CONTRACTOR has either
given written release of results of the tests conducted at such premises, or ordered
shipment without such release.

14.0 ADDITIONAL REQUIREMENTS

14.1 NOISE

The noise level of each operating equipment (including drivers where applicable) shall
be in accordance with Project Equipment Noise Control Specification DGS-MU-009.

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14.2 PERFORMANCE

MANUFACTURER/VENDOR shall guarantee that the equipment will meet the


requirements indicated on the individual Equipment Data Sheets.

14.3 IDENTIFICATION AND TAGGING

Nameplates

A corrosion resistant metal nameplate shall be permanently attached to the equipment


(not baseplate) and contain the following information using specified units:

PO Number

Equipment Item Number

MANUFACTURER/VENDORS Name

Serial Number

Rated Capacity

Size and Type

Year Built

This instruction is not intended to supersede or supplement the requirements of the


governing codes and standards.

Marking

Connections furnished on the purchased equipment shall be impression stamped or


permanently tagged to agree with MANUFACTURER/VENDORS connection table or
general arrangement drawing.

Tagging

All items shipped loose shall be identified with its PO Number and Item Number. Tags
shall be corrosion resistant metal (not aluminum) and impression stamped with the
following information:

PO No.

PO Item No.

Equipment Item No.

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Tags shall be attached to each component with stainless steel wire. Equipment shipped
in fully enclosed containers also shall include the above information marked on the
outside of the container.

14.4 SPARE PARTS

The MANUFACTURER/VENDOR shall provide spare parts requirements in accordance


with Project Spare Parts Specification DGS-MU-003.

14.4 LUBRICATION

MANUFACTURER/VENDOR shall submit recommended lubrication schedule and


lubrication material for each tag item in accordance with Project Lubrication
Requirements Specification DGS-MU-004.

14.5 SPECIAL TOOLS PROVIDED BY VENDOR

VENDOR shall furnish all special tools required for installation, commissioning,
disassembly, and reassembly of the equipment. VENDOR shall provide with his
proposal a list of special tools included in his offer. For multi-unit installations, VENDOR
shall provide one set of special tools for each pair of units. Special tools required for use
during normal operation shall be suitable for the specified area classification. All special
tools shall be packaged in metal containers.

Adequate documentation/specs shall be provided for the special equipment & tools.
Impact tools shall be non sparking type (Brass or other).

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ADDENDUM SHEET

All revisions to this DGS subsequent to the issue of Rev Zero shall be recorded in this addendum
sheet and shall be incorporated into the DGS in the next revision.

Date Proposed Revision Remarks

May 2009 AMD-MU-001-BECHTEL Incorporated in


Revision 1

In Clause # 2.0: Addition/Deletion/Replacement /Modification

Modify Last sentence of 2nd Paragraph as:

The edition in force at the time of CONTRACTORs / VENDORs


proposal shall apply.

Replace: ASME B31.3 Chemical Plant and


Petroleum Refinery Piping.

With: ASME B31.3 Process Piping.

Replace: AWS-A3.0 Terms and Definitions.

With: AWS-A3.0 Standard Welding Terms


and Definitions.

Replace : AWS-D1.1 Structural Welding Steel

With: AWS-D1.1 Structural Welding for Steel


Delete reference to: EN 102044 and replace with EN 10204

Delete reference to: ISO 9011 and replace with ISO 19011

In Clause # 4.0: Addition/Deletion/Replacement /Modification

Add Following New Sentence at the start of the Clause:

It shall be the Subcontractor/Vendor's responsibility to be, or to


become, knowledgeable of the requirements of the referenced
Codes and Standards.

Replace: The VENDOR shall notify the CONTRACTOR of any


apparent conflict between this specification, the
related data sheets, the Codes and Standards and
any other specifications noted herein.

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With: The Subcontractor/Vendor shall bring to Contractor's


attention, any apparent conflict between this
specification, the related data sheets, the Codes and
Standards and any other specifications mentioned
herein.

In Clause # 6.0: Replacement

Replace: VENDORS proposed quality system shall fully


satisfy all elements of ISO 9001 2000 and ISO
9004 2000.

With: VENDORS proposed quality system shall fully


satisfy all elements of ISO 9001 2000 and ISO
9004 2000 with due regard to ISO 19011.

In Clause # 7.0: Addition/Replacement

Replace: Official Trade name of the Company

With: Official Trade name of the


Manufacturer/Vendor.

Add New Bullet Point as:

Companys Name/Pant Site and Unit

In Clause # 10.0: Addition/Replacement

Replace: The equipment shall be designed for a minimum


service life of 30 years and 4 years uninterrupted
operation.

With: The equipment shall be designed for a minimum


service life of 30 years and 5 years uninterrupted
operation.

Add following sentences at the end of in this clause:

Equipment selection shall be based on the approved


VENDORS list for the PROJECT and according to the
applicable standards. The equipment shall be designed
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and selected considering the local environment to reflect


the optimum maintenance policy consistent with safe and
efficient operation. Where the equipment needs to be
designed on sound Engineering judgment different from
that mentioned above, COMPANY approval for variance
shall be sought.

Due consideration shall be given for field proven latest


state-of-the art technology and features for the equipment.
In such cases, adequate backup documentation shall be
provided by the proposed VENDOR furnishing sufficient
and satisfying evidence that the updated ones are widely
used for a length of time in similar and comparable
industrial environment.

Long term maintainability and life cycle analysis for any


major equipment, to optimize maintenance, costs shall be
considered in the selection.

In Clause # 11.0: Replacement

Replace: VENDOR shall furnish Material Certificates in


accordance with the requirements of EN 102044
(formerly DIN 50049). The type of certificate
required A, B, or C is determined by the
inspection class assigned to the type of
equipment or material.

With: VENDOR shall furnish Material Certificates in


accordance with the requirements of EN 10204
(formerly DIN 50049). The type of certificate
required 2.1, 2.2, 3.1 or 3.2 is determined by
the inspection class assigned to the type of
equipment or material.

In Clause # 14.5: Addition

Add following sentences at the end of in this clause:

Adequate documentation/specs shall be provided for the special


equipment & tools. Impact tools shall be non sparking type (Brass
or other).

Oct 2011 AMD-MU-001-002, Rev.2 Incorporated in


Revision 2

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In Clause # 3.0: Addition


Add new reference document to the list as given below :

Health, Safety and Environmental (HSE):

ADNOC-COPV6-01 Identification and Integrity Assurance of


HSE Critical Equipment and Systems

HSE-CP20 HSE Critical Equipment & Systems

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