NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES A.01

PLANT LAYOUT AND SPACING

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

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INDEX

SECTION TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Area Classification 7

4.0 GENERAL REQUIREMENTS 7

4.1 General 7
4.2 Environmental Effects 7
4.3 Fire and Emergencies Protection 7
4.4 Maintenance and Operation 7
4.5 High Risk Equipment 8
4.6 Site Security 8
4.7 Climatic Design Data 8
4.8 Site Drainage/Effluent Collection 8
4.9 Future Expansion 8

5.0 PROCESS UNITS LAYOUT 8

5.1 Optimum Layout 8

5.2 Plot Plan 9
5.3 Spacing of Process Equipment 9
5.4 Pipe Racks 10
5.5 Access Roads within Plot Limits 10
5.6 Major Maintenance Areas 10
5.7 Access Clearances 11
5.8 Platforms, Stairways and Ladders 11

6.0 PROCESS EQUIPMENT LAYOUT 12

6.1 Structures for Equipment 12

6.2 Pumps 13
6.3 Compressors 13
6.4 Fired Heaters and Boilers 14
6.5 Air Intakes and Exhaust Stacks 15
6.6 Chemical Injection Areas 15
6.7 Air-cooled Heat Exchangers 16
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SECTION TITLE PAGE

6.8 Towers/Columns 16
6.9 Control Rooms/Control Buildings 16
6.10 Electrical Sub-Stations 17

7.0 SITE LAYOUT AND OFF-SITES 17

7.1 Overall Site Plot Plan 17

7.2 Plant Access Roads 18
7.3 Utility Plant 18
7.4 Buildings 19
7.5 Paving and Drainage 19

8.0 OFF-SITES EQUIPMENT LAYOUT 19

8.1 Cooling Towers 19

8.2 Flares and Vent Stacks 20
8.3 GOSP Facilities 20
8.4 Loading Facilities 21
8.5 Tank Farms 21
8.6 Pressurised Storage 22
8.7 Oil/Water Separators and Skimming Ponds 23

Figure No. 1 Overall Layout Showing Hazardous Areas 24

Figure No. 2 Optimum Process Unit Layout 25
Figure No. 3 Equipment Maintenance Access 26
Figure No. 4 Distance Between Process Plants 27
Figure No. 5 Process Plant Minimum Spacing 28
Figure No. 6 Bunded Area Minimum Distances 29
Figure No. 7 Tank Farm Minimum Distances 30
Figure No. 8 Minimum Safety Distances for above ground LPG
Pressure Storage Vessels 31
Figure No. 9 Impounding Basin 32

Table 1A Minimum Spacing for Refineries, Chemical 33

Plants and Oil/Gas Facilities (FPS Units)

Table 1B Minimum Spacing for Refineries, Chemical Plants and Oil/Gas

Facilities (Metric Units) 34
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for layout and spacing of equipment for refineries, oil
and gas onshore installations and processing facilities.

1.1.2 The provisions laid down in this specification shall be complied with in full and any exceptions must be
authorised in writing by the Owner.

1.1.3 In the event of any conflict between this specification and any of the applicable codes and standards, the
contractor shall inform the Owner in writing and receive written clarification before proceeding with the
work.

1.1.4 This General Engineering Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner.

Where indicated in this specification, the following NOC Specifications shall apply:

GES A.03 - Packaged Units Layout, Spacing and Assembly

GES A.06 - Site Data

GES B.02 - Blast Resistant Control Buildings

GES H.04 - Fire Water Systems

GES H.06 - Fixed Water Spray Systems

GES H.07 - Fire Fighting Facilities for Storage Tanks

GES L.31 - Area Classification

GES P.02 - Plant Piping Systems

GES Q.03 - Foundations and Piling

GES Q.04 - Concrete Structures

GES Q.06 - Roads and Paving

GES Q.14 - Design Loads for Structures

GES R.06 - Marine Loading Facilities

GES S.01 - Steelwork Structures

GES S.02 - Structures for Operation and Maintenance

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2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Dropout Area

A designated maintenance area adjacent to elevated equipment or structures to accommodate the lowering
of equipment internals, such as tower trays, by means of a davit fixed to the tower. Other applications may
apply, such as catalyst loading and unloading at reactors and dehydrators.

Laydown Areas

A designated maintenance area local to rotating or other mechanical equipment where space is restricted,
such as in a compressor building. For example, the casing of a compressor can be lifted and laid down in a
specific area so that the compressor machinery can be inspected and maintained.

Tube (or Bundle) Pulling Area

A designated area to allow the pulling of removable tube bundles from heat exchangers and condensers.
This definition also applies to the removal of furnace tubes for fired heaters.

Bunded Area (also known as a Diked Area)

A retaining area surrounding a storage tank or group of tanks sized to contain the contents of the largest
tank (plus the additional cubic capacity occupied by the remaining tanks, up to the level of the bund wall)
in the designated area in case of rupture of the tank wall.

Bund walls (or Dikes) are normally earth walls with sloped consolidated sides. Concrete bund walls are
sometimes used for smaller storage tanks or in restricted areas.

Maximum Heat Radiation Flux Level (Heat Flux)

This is the maximum allowable heat flow emitted by a flare or a fire that may be tolerated by operating
personnel and equipment.

This factor is measured in either BTU/h ft2 or kW/m2 (the latter is more recognised).

The maximum continuous human tolerance without protective clothing is a heat flux of 500 BTU/h ft2
(1.5 kW/m2). The maximum allowable heat flux for process units is 2000 BTU/h ft2 (6 kW/m2).

Sterile Area

Area surrounding a flare stack, with controlled access (subject to "Work Permit" restrictions). Total
destruction of vegetation to avoid ignition.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

2.2.1 Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

2.2.2 Purchaser
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The company buying the equipment for or on behalf of the Owner.

2.2.3 Vendor

The company supplying the equipment and material.

2.2.4 Contractor

The main contractor for a defined piece of work.

2.2.5 Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

2.2.6 Inspection Authority

The organisation representing the Owner, Purchaser or Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

2.2.7 Inspector

A qualified individual representing the Owner, Purchaser, Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

3.1.1 The design shall comply with this specification and the following codes and standards.

Institute of Petroleum (IP)

Model Code of Safe Practice - Part 3 Refining Safety Code

Model Code of Safe Practice - Part 9 Liquefied Petroleum Gas

National Fire Protection Association (NFPA)

NFPA Standard No.30 Flammable and Combustible Liquid Code

American Petroleum Institute (API)

API 2510 Design and Construction of LPG

Installations

American National Standards Institute (ANSI)

ANSI B31.3 Process Piping

ANSI A99.10 Uniform Building Code, Earthquake
Regulations

Oil Insurance Association

Publication No. 631 General Recommendations for Spacing

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LP Gas Association

LPG Codes of Practice Code of Practice No.1 Installation and

Maintenance of Fixed Bulk LPG Storage:
Part 1 Design and Installation

3.1.2 Unless specified otherwise in the Purchase Order/Contract, the current editions of the codes and standards
at the time of the Order shall be used.

3.2 Area Classification

3.2.1 General

Area classification divides the plant into areas based on the probability of combustible materials being
present in that area. Classifications shall be in accordance with General Engineering Specification GES
L.31

4.0 GENERAL REQUIREMENTS

4.1 General

Process plants, units and equipment shall be arranged by the Vendor/Contractor to provide an economical
facility which shall be safe and easy to operate. In order to develop a detailed layout of a refinery,
petrochemical installation or an oil or gas onshore production facility, a number of studies and
investigations are needed and shall be carried out, i.e. soil conditions, plant location, environmental impact,
pipeline routes, public utility connections (if any), air, road or sea access. Requirements for future
expansion shall be allowed for by the Vendor/Contractor.

4.2 Environmental Effects

Distance from other industrial (i.e. source of ignition) and residential areas shall be considered.
Installations shall not endanger the environment under normal operating or emergency conditions. These
conditions shall thus determine the boundary fence limits.

4.3 Fire and Emergencies Protection

Critical emergency facilities shall be easily accessible for operators to perform emergency shutdown
actions in the case of a fire or an explosion.

The layout should provide accessibility for fire-fighting and emergencies, and to minimise involvement to
adjacent facilities in a fire (see Figure 1 for typical model). Minimum separation distances are laid down in
Table 1A (1B).

4.4 Maintenance and Operation

The layout should provide easy access for plant personnel and vehicles for normal operation and
maintenance of equipment.

Separation distances between units should enable maintenance to be carried out safely in one unit, with
adjacent units in operation (see Figure 2).

4.5 High Risk Equipment

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High risk equipment (i.e. Process Unit Fired Heaters) or facilities shall be segregated (as practically
possible) from less hazardous equipment (i.e. Atmospheric Storage Tanks) and operations.

4.6 Site Security

Site security shall be achieved by providing appropriate boundary fencing and gates. The level of site
security shall be determined by the Owner.

4.7 Climatic Design Data

The prevailing wind direction should be determined and shown on the site plot plan and the process plot
plan(s). Maximum and minimum ambient temperatures and maximum precipitation should be established.
Note: For all climatic design data i.e. earthquake zoning etc., refer to General Engineering Specification
GES A.06.

4.8 Site Drainage/Effluent Collection

The main collection points for rain water and effluent shall be located at the lowest elevation corner of the
site to utilise the natural ground slope (preferably downwind).

4.9 Future Expansion

Future expansion shall be assessed and space allocated for known and unforeseen future requirements.
Orderly expansion shall be achieved by providing space adjacent to a similar type of facility. Extensions to
pipe sleepers, pipetracks, road crossings and yard piping shall be given due consideration. Care shall be
taken to facilitate future expansion without any interference to existing plant on stream.

5.0 PROCESS UNITS LAYOUT

5.1 Optimum Layout

The typical process unit layout as shown in Figure 2 is called a `finger-layout' and is recommended for
optimum economy, maintenance and operation. If there are multiple units, they should be laid out side by
side with the `finger' racks at 90° to the main pipe bridge.

Air-fin coolers are preferably located on top of the unit piperacks. On one side of the piperack, all low
equipment such as horizontal heat exchangers, pumps, etc., are to be located and on the opposite side, high
equipment such as columns, vertical drum, structures, etc., are located. In this way a crane can be operated
to reach all equipment, see Figure 3.

On the other side of the main pipe bridge, furnaces and heaters can be located with a minimum distance of
50 ft (15 m) from process equipment, and 15 ft (5 m) from the main pipe bridge. Reactors and heat
exchangers associated with the furnace area, and which are also above auto-ignition temperature, may be
located within 50 ft (15 m) of the furnaces.

5.2 Plot Plan

5.2.1 General

A process area plot plan shall be produced by the Vendor/Contractor preferably at a scale of _ in = 1 ft
(1:100 m) or at a scale specified by the Owner. The battery limit "BL" of the process area plot plan shall be
clearly defined to establish the contractor's responsibilities. Each corner of the "BL" shall be identified
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using the established plant grid co-ordinates of northings and eastings "NE". The plot plan shall show the
used location of all equipment, piperacks, buildings and access roads. Major maintenance areas for
exchanger bundle pulling, etc., shall also be shown. A table on the right-hand side of the drawing shall list
all equipment items with their designation, titles and with base support or centreline elevations.

5.2.2 Equipment Designation

All equipment shown on the plot plan shall be designed and classified as follows:

Class A - Packages
Class B - Boilers and Deaerators
Class C - Columns or Towers
Class D - Drums
Class E - Exchangers or Condensers
Class F - Furnaces
Class GT - Gas Turbines
Class K - Compressors
Class M - Miscellaneous or Special Equipment
Class P - Pumps
Class R - Reactors or Dehydrators
Class ST- Steam Turbines
Class T - Atmospheric Storage Tanks
Class V - Pressurised Storage Vessels
Class WD - Well Heads

5.2.3 Elevations

A datum level of 100′-0″ (100.000 m) shall be established for the process plot area. This datum is the
height of finished grade, and is the equivalent of the national survey datum for the area.

For example: datum elevation 100′-0″ = 15′-3″ national datum, or

(datum elevation 100.000 m = 4.650 M)

5.2.4 Escape Routes

Designated emergency escape routes shall be shown on the plot plan. These routes shall be as straight and
as easy as possible for access. Escape routes shall not be impeded in any way by equipment or piping and
shall be a minimum of 6′-6" (2m) wide when used as a walkway.

5.3 Spacing of Process Equipment

Within process plot limits, the location of process equipment and major facilities, such as control buildings,
electrical substations, etc., shall be determined in accordance with the Spacing Chart, Table 1A (1B), with
consideration given to the proximity of adjoining facilities, prevailing wind direction and site topography.

5.4 Pipe Racks

5.4.1 General

A minimum distance should be maintained between the outside edge of equipment and a piperack to
prevent a `chimney' effect in case of a fire see table 1A (B). This free space can also provide maintenance
access.

An exception of this rule may be made for pumps, subject to Owner's approval.
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5.4.2 Clearances

An access clearway, 16ft (5m) wide by 18ft (5.5m) clear high shall be provided under the entire length of
the main pipe rack. The clearway should not be obstructed by ladders, equipment etc., and shall be
accessible from the main plant road from both ends. Secondary pipe racks shall have an access of 12ft
(3.6m) wide by 14ft (4.2m) clear height shall be provided under the entire length. A clear height of 18ft
(5.5m) under major pipeways shall also be provided for major mobile equipment and fire fighting access,
all other process pipeways shall have a minimum clear height underneath of 14ft (4.2m).

Pipe racks located near hazardous equipment shall be fireproofed. The fireproofing shall include all the
steel support columns, beams, and bracing, the top face of the beam flange does not require fireproofing.

Piping located at ground level on sleepers shall have a minimum clearance from the finish grade (refer to
GES P.02 paragraph 9.6).

Note: Corner columns at junctions with the main pipe rack, shall be protected by a curb or steel ers.

5.5 Access Roads within Process Plot Limits

5.5.1 General

The process area shall be provided with (all weather surface) access roads for fire-fighting, maintenance,
and operations. Access roads shall be wide enough to provide space to manoeuvre during fire fighting.

Provision shall be made for at least two entrances to a process area from a main plant road system. (See
Figure No 1).

5.5.2 Clearances and Dimensions

Main access roads within the process area shall be 20 ft (6 m) wide. Minor accessways shall be 13 ft (4
m) wide. A minimum distance of 20 ft (6 m) is required from the edge of equipment to the edge of a main
access road. The distance between two major intersections should not exceed 100 ft (30 m). A minimum
distance of 6 ft (2 m) is required from the edge of equipment to the edge of minor accessways.

5.6 Major Maintenance Areas

Requirements for drop-out areas, laydown areas and bundle pulling areas shall be considered in the layout.
All of these areas shall have direct access to plant access roads.

Bundle pulling areas should not encroach upon major access roads.
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5.7 Access Clearances

Minimum clearances for operator and maintenance access shall be as follows:

(a) Overhead Clearances

Over plant roads for major mobile equipment - 18 ft (5.5 m)

Over process plant access roads - 14 ft (4.2 m)

Clear access under piperacks:

(i) where vehicle access is required - 18 ft (5.5 m)

(ii) for portable service equipment - 14ft (4.2 m)

Over pumps and drivers - 8 ft (2.4 m)

Personnel headroom at walkways, passageways - 7 ft (2.150 m)

and platforms

(b) Horizontal Clearances

At end of pump drivers:

(i) when truck access is required - 10 ft (3.0 m)

(ii) when truck access is not required - 5 ft (1.5 m)

Distance required to remove tube bundle from - tube length, plus

exchanger (from face of shell cover flange) 2 ft (0.6 m)

Distance required to remove rear exchanger cover - 3.5 ft (1.070 m)

In front of manways (include any insulation) - 3 ft (1 m)

For walkways at grade and on elevated platforms - 2.5 ft (0.76 m)

Main operating aisles, escape routes - 4 ft (1.2 m)

Behind control panels - 4 ft (1.2 m)

5.8 Platforms, Stairways and Ladders

5.8.1 General

Platforms are required for operation and maintenance access for elevated equipment. All operational
valves, spectacle blinds and instruments shall be accessible, and where necessary, platforms shall be
installed.

5.8.2 Location

Platforms shall be located in accordance with GES S.02, Sections 3 and 5. Stairs and ladders shall be
provided and located in accordance with GES S.02, Sections 3 and 4.

In addition to the above, all ladders shall face toward the equipment or structure being served. All stair and
ladder locations at grade for major equipment and structures shall have clear access to a plant road for
emergency escape.
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6.0 PROCESS EQUIPMENT LAYOUT

6.1 Structures for Equipment

6.1.1 General

Structures shall be provided for equipment that is elevated for process requirements, (i.e. a reflux cascade
system for a column or tower, or where there is a lack of plant space). The last option shall be minimised
because of additional cost and increased fire risk.

6.1.2 Location

A minimum clearance of 10 ft (3 m) is required between the outside face of structure columns and the
outside face of piperack columns. Where the structure is adjacent to equipment, a minimum clearance of
10 ft (3.0 m) is required between the edge of equipment to the outside face of structure columns.

Whenever possible, the centreline of structure columns should line up with the centreline of piperack
columns to facilitate ease of pipe routing.

For details of steelwork structures, see GES S.01. For details of concrete structures, see GES Q.04.

6.1.3 Spacing

Horizontal spacing of equipment contained within a structure shall conform to Table 1A (1B), Spacing
Chart. The overall horizontal dimensions of the structure shall contain the limits of the equipment without
any overhang. A minimum of 3 ft (1.0 m) wide access is required between equipment and associated
piping and the edge of the structure platform.

Vertical spacing between structure levels shall provide adequate vertical clearances for the normal
operation and maintenance of equipment and piping.

6.1.4 Access

Main access to the structure shall be by a stairway at the side of the structure, unless it is a minor structure
of one level only and is 12 ft (3.7 m) high or less, when a ladder will suffice.

The escape route shall be by ladder access, diagonally opposite to the main stair access.

The stairway shall not be located between the structure and a piperack, or between the structure and a
maintenance access road.

6.1.5 Maintenance

Consideration shall be given to the maintenance of exchangers and other equipment on intermediate levels
of the structure. Runway beams or davits (where necessary) shall be provided for exchanger bundle pulling
or bonnet removal, etc.
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6.2 Pumps

6.2.1 General

Pumps shall be installed alongside the piperack with the pump centrelines at 90° to the piperack, with a
minimum clearance from the back of pumps to the piperack column centreline of 5 ft (1.5 m). All pump
drivers shall face towards the piperack.

6.2.2 Access

All pumps shall be accessible for operation and maintenance, with a minimum access of 3 ft (1 m) between
the pumps. This access shall be clear of obstructions such as valve handwheels, pipe manifolds, etc.
Particular consideration shall be given to steam turbine drivers to provide adequate clearance from the
steam piping to the adjacent pump. Auxiliary equipment for large capacity pumps, such as lube and seal oil
consoles, shall be allowed for in the layout. Suction, discharge and auxiliary piping shall not cross over the
pumps and drivers.

6.2.3 Spacing

Spacing in relationship to other equipment shall be governed by the Spacing Chart, Table 1A (1B).

6.2.4 Location

Pumps a source of hydrocarbon leakage shall not be located below tower platforms, structures, elevated
drums, air-cooled heat exchangers or piperacks. Pumps shall be mounted on a concrete base with a
minimum height of 200 mm above grade to the pump baseplate.

6.3 Compressors

6.3.1 General

Compressors shall generally be located in a compressor house or shelter. The steel framework of the
building shall carry a travelling crane for machinery maintenance. The sheeting walls of the compressor
shelter are normally open sided, with a minimum clear height of 8 ft (2.5 m) from grade to the underside of
the sheeting.

Large centrifugal compressors shall normally be elevated and mounted on a concrete table top, to facilitate
gravity drainage of oil systems to the lube oil and seal oil consoles located below at grade. Where a steam
turbine driver is installed, additional elevation of the machine shall be provided to facilitate the
arrangement of the surface condenser below the steam turbine.

Reciprocating compressors shall be located near to grade, to minimise vibration effects on the machinery
foundations and on the compressor piping.

For details of structural steelwork for compressor shelters, refer to NOC GES S.01 and GES S.02.

For details of compressor foundations and concrete table tops, refer to NOC GES Q.03, GES Q.04 and
GES Q.14.

6.3.2 Location

Compressors shall be located in relation to other equipment in accordance with Table 1, except for
equipment directly associated with the compressors, such as knock-out drums, lube and seal oil consoles,
which may be located in the compressor area.

A compressor area shall not be located in the middle of a process plant for the following reasons:
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(a) The hazardous nature of gas compressors handling hydrocarbon fluids.

(b) External construction activity at a compressor area, including installation of heavy machinery,
which could have a late scheduled on site delivery. The compressor area shall be located close to
or at the periphery of the process plant.

6.3.3 Spacing

Where two or more compressors are to be installed within a compressor shelter, the minimum spacing
between machines shall be 10 ft (3 m). Compressors handling inert gas or air may be located closer to each
other. Consideration shall be given to maintenance requirements, such as laydown areas, and the location
of auxiliary equipment. Provision shall be made for the removal of pistons from horizontally opposed
cylinder type reciprocating compressors. Steam turbine or electric motor driven compressors with drivers
less than 150 kW power may be treated as pumps for spacing and location purposes.

6.3.4 Maintenance

The handling of component parts and removable casings of the compressor and driver shall be carried out
by using a travelling crane within the compressor shelter framework.

The range of the travelling crane shall cover the entire compressor machinery area, including auxiliary
equipment. Where required, in the case of a table-top arrangement, sections of the operating platform shall
be made removable so that the crane can be used for handling equipment at grade.

There shall be a clear laydown area at one end of the compressor shelter, within the range of the crane.
This laydown area shall form the end of an accessway 12 ft (4 m) wide that is directly connected to a main
plant road.

The crane hook shall be at a minimum height to enable the largest component or casing to be lifted over the
remaining equipment en-route to the laydown area with a clearance of at least 2 ft (0.6 m).

6.4 Fired Heaters and Boilers

6.4.1 General (Fired Heaters only)

Fired Heaters are generally of two types, the cabin or rectangular type and the vertical circular heater.
Location and spacing requirements apply equally to both types.

6.4.2 Location

Fired Heaters and boilers form a hazard to the remainder of the process plant because of their constant
source of ignition. The required location shall be on the upwind side of the plant and close to the battery
limit. See Figure 2 "Optimum Process Unit Layout" and Table 1A (1B) "Minimum Spacing for Refinery
Chemical Plants and Oil/Gas Facilities".

Consideration should be given to any adjacent units or facilities, in particular those containing hazardous
equipment. The top of a furnace stack shall be a minimum of 10 ft (3 m) above any working platform.

Note: In some circumstances a bund wall may be required around the Fired Heaters to contain spillage.
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6.4.3 Spacing

Spacing shall be in accordance with Table 1, Minimum Spacing Chart, but generally equipment containing
combustible materials shall be a minimum of 50 ft (15 m) from furnaces or heaters, except equipment
directly associated with the furnaces and within the furnace areas. Spacing between furnaces shall be 25 ft
(7.5 m) if the pressure at the coil inlet is 100 psig (6.8 bar g) or less, and 50 ft (15 m) if above 100 psig (6.8
barg).

6.4.4 Maintenance Access

In addition to the spacing requirements above, a maintenance area shall be provided for the pulling of
furnace coils. This area is to be adjacent to a major plant road.

6.5 Air Intakes and Exhaust Stacks

6.5.1 General

Air intakes and exhaust stacks are required for certain items of equipment within a process area. For
example, heating and ventilation, air compressors, forced draft furnaces, gas turbines and internal
combustion engines. Additionally, atmospheric exhausts may be required for start-up systems, turbine
exhausts and relief valve discharge piping.

6.5.2 Location

Air intakes can be a potential source of ignition, whereby they can pull in flammable vapours and create an
internal explosion. The location of air intakes shall be carefully considered in relation to other equipment
and the prevailing wind direction.

Atmospheric exhausts shall be located so that they do not present a hazard to personnel or equipment.

Atmospheric exhausts should thus be located a minimum of 10 ft (3 m) above any platform within a
horizontal distance of 25 ft (7.5 m). Exhaust lines shall be run together, where possible, in a vertical bank
to a high point of an area. Manhole vents from oily water sewer systems should be run to a piperack or
structural column, and provided with a flame arrestor at the open end of the vent. They should follow the
vertical and horizontal rules given above for atmospheric exhausts.

6.6 Chemical Injection Areas

6.6.1 General

Equipment containing caustic fluids or any other chemicals which would cause injury to the eyes or body
of any person exposed to accidental spillage or leakage, shall be located in accordance with paragraph 6.6.2
below.

6.6.2 Location

Equipment containing caustic or other fluids hazardous to personnel shall be grouped together and shall be
surrounded by a curb 6 in (150 mm) high for containment of accidental spillage. There shall be a 3.25 ft (1
m) access between the edge of the equipment and the inside edge of the curb.

An emergency shower and eyewash fountain shall be provided no further than 50 ft (15 m) unobstructed
access from the caustic area. The safety shower and eyewash shall be provided with a potable water
supply. Safety signs with pictorial displays shall also be provided close to the area.

6.7 Air-cooled Heat Exchangers

6.7.1 General
 GENERAL ENGINEERING SPECIFICATION GES A.01
PLANT LAYOUT AND SPACING Page 16 of 34
Rev 0 1999

Air-cooled heat exchangers are particularly vulnerable to fire damage due to the materials used in the large
surface areas required for heat transfer, thus careful consideration should be given to the location of air-fin
exchangers to minimise possible loss from fire.

6.7.2 Location

Air-cooled heat exchangers shall be located as far away as possible from a furnace area.

Economy of process plant space and the cost effective use of structural steelwork, normally dictate that air-
fin coolers are located over a piperack. The following requirements to minimise fire damage shall apply:

(a) A fire deck shall be installed below air-fin coolers when flammable gas or liquid containing
equipment is installed below.

(b) Minimum headroom of 10 ft (3 m) shall be provided between the lowest part of an air-fin
exchanger and the top of the piperack.

(c) Flanged joints shall be minimised in all hydrocarbon lines below air-fin exchangers.

(d) Clear access to one side of the piperack shall be provided for fire-fighting and maintenance.

(e) Column supports for piperacks and air-cooled exchangers shall be fire-proofed as far as the air-
cooled exchanger supports.

6.8 Towers/Columns

6.8.1 Location

Towers/columns shall be located along the pipe rack towards open areas, to allow unobstructed erection
and maintenance of internals. Tall towers require frequent operating attention at higher levels, hence (if
possible) they shall be located in one place for common access.

6.9 Control Rooms/Control Buildings

6.9.1 Location

Control Rooms/Control Buildings shall be located distinctly in the process block or in the adjoining block.
The Control Room/Building may be dedicated to one process unit or shared by two or more process units
of similar function. The Control Room/Building shall be at a safe distance, where protection to personnel
and instruments is ensured and non-hazard electrical area classification is permitted.

Notes:-

(1) Safe distances from equipment shall be in accordance with Table 1A (B).

(2) Control room/building locations in a `high' hazard process unit shall be specified as "Blast
Resistant"
 GENERAL ENGINEERING SPECIFICATION GES A.01
PLANT LAYOUT AND SPACING Page 17 of 34
Rev 0 1999
6.10 Electrical Sub-Stations

6.10.1 Location

The unit Electrical Sub-Station shall be located in a non-hazardous area, as near as possible to the "Load"
centre of the area to be supplied. The sub-station shall be preferably be located adjacent to the Control
Room/Buildings. When sub-stations are located within the process block limits, care shall be taken that
they meet the requirements of the electrical area classification and shall not be sited in the drainage path
from hydrocarbon handling equipment.

Transformers shall be located in open area at the rear of the sub-station. Each transformer shall be isolated
from the others by a masonry wall.

An access road to the sub-station and transformer bays shall be provided to facilitate crane movement for
erection and maintenance.

Note: Pipelines and buried facilities in the area shall be avoided.

7.0 SITE LAYOUT AND OFF-SITE

7.1 Overall Site Plot Plan

A site plot plan shall be produced by the Vendor/Contractor at a scale to suit the size of the plant and shall
be agreed by the Owner, but in no case shall be less than 1/32" = 1ft (1:400m).

This drawing shall give the following information:

(a) A co-ordinate datum point (S.O.P. = setting out put) from which all site locations shall be taken
with north and east coordinates.

(b) Indication of plant north, in relation to true and magnetic north.

(c) The prevailing wind direction.

(d) The finished grade level for specified areas based on the national survey datum.

(e) The perimeter site fence limits, including plant entrance gates and gate houses.

(f) The location of process units, off-site storage, utility plant, flares, vent stacks and buildings.

(g) The location and elevation of all plant access roads.

(h) Areas for future expansion.

(i) The location of pipeways and main utility services.

(j) Existing facilities or buildings adjacent to the site shall be shown where possible.

(k) All major tie-in points for product, utilities, and main services shall be identified at the battery
limit.
 GENERAL ENGINEERING SPECIFICATION GES A.01
PLANT LAYOUT AND SPACING Page 18 of 34
Rev 0 1999
7.2 Plant Access Roads

7.2.1 General

The layout of access roads shall provide a means of access for operating and normal maintenance
equipment and for fire-fighting vehicles to all parts of the plant.

For design details of all roads, refer to General Engineering Specification GES Q.06.

7.2.2 Road Categories

Three classes of roads are normally used for refineries, oil and gas onshore installations and processing
facilities.

(a) Primary Roads

These carry general unrestricted traffic with direct access to the public highway from the
site entrances. Primary roads shall be 26 ft (8.0m) wide, with 5 ft (1.5 m) wide shoulder
on each side.

(b) Plant Access Roads

These carry normal maintenance vehicles and fire-fighting equipment within the process
and off-site areas. Plant access roads shall be 20 ft (6.0 m) wide, with 3 ft (1.0 m) wide
shoulder on each side.

(c) Secondary or Minor Accessways

These are restricted access roads within a process or off-site area and carry mobile
maintenance vehicles and cars. Accessways shall be a minimum of 12 ft (4 m) wide, with
no shoulders provided.

All road categories shall be surfaced with asphalt or concrete.

7.2.3 Layout

The road layout shall provide access for fire-fighting vehicles to all sides of a process block, and to bunded
storage areas within a tank farm.

Turning radii at road junctions shall be designed to facilitate movement of the largest fire-fighting vehicle
in the event of an emergency or a minimum radii of 20 ft (6m).

A perimeter road inside the boundary fence shall be provided when specified by the Owner.

Provision shall be made for at least two entrances to process units, utility plants and tank farms. Main
administration buildings and car parking shall be accessible from a primary road.

Road junctions shall be no more than 100 ft (30 m) from each other in areas where fire-fighting access is
required.

7.3 Utility Plant

Utility plants shall have maximum protection with respect to location and spacing, and shall always be
easily accessible in emergency conditions.

Utility plants shall be divided into two areas, one containing flammable products, such as oil, fuel oil, fuel
gas, etc., and the other containing non-flammable products, i.e. instrument air, boiler feed water, water
 GENERAL ENGINEERING SPECIFICATION GES A.01
PLANT LAYOUT AND SPACING Page 19 of 34
Rev 0 1999
storage, nitrogen, etc. The flammable area shall be treated as a process area containing hydrocarbon and
should follow the requirements laid down in Section 5 of this specification.

The steam generating facilities shall be located in the area containing flammable products. Boilers shall be
located up-wind from fuel oil or diesel oil storage tanks.

7.4 Buildings

7.4.1 Control Buildings

The minimum distance of control buildings from process areas or other facilities containing hydrocarbon
fluids shall be in accordance with Tables 1A (B).

7.4. Service Buildings

Service buildings such as administration buildings, workshops, laboratories, etc., shall be located upwind
from hydrocarbon processing plant. Personnel in these buildings are not directly involved with plant
operation, thus these buildings may be remotely located from the process facilities. Minimum distances
from process plant and other facilities shall be in accordance with Tables 1A (B).

7.4.3 Analyser Houses

The location of an anaylser house should be in accordance with normal refinery practice, i.e. within the
battery limits of a process area. There shall be a minimum distance of 50 ft (15 m) from furnaces. There
shall be an access way of 10 ft (3 m) on all sides of the analyser house.

7.5 Paving and Drainage

Paved areas shall be decided upon after examination of the entire plant area, including roads and after
taking into account the following factors:-

(a) Paved areas shall be provided to prevent hazardous liquids from soaking into the ground from
machines, pumps, flange joints at vessels, control value assemblies, filters etc.

(b) Paving shall be provided where regular use of scaffolding occurs.

(c) Small areas of un-paved ground between larger areas shall be avoided.

(d) All paved areas shall be drained to convey liquid quickly to a proper underground drainage
system.

8.0 OFF-SITES EQUIPMENT LAYOUT

8.1 Cooling Towers

Cooling towers shall be located downwind to minimise the effect of external corrosion on other areas of
equipment from exhaust plume. Towers shall be located in accordance with Tables 1A (B) "Minimum
Spacing for Refineries, Chemical Plants and Oil/Gas Facilities".
 GENERAL ENGINEERING SPECIFICATION GES A.01
PLANT LAYOUT AND SPACING Page 20 of 34
Rev 0 1999
8.2 Flares and Vent Stacks

8.2.1 General

Flares, burn pits and vents shall be located downwind and built in an open area. The prevailing wind
direction and site topography should be considered when locating a flare or vent stack.

8.2.2 Elevated Flares

A flare is considered elevated if it is above 50 ft (15 m) high. A sterile area is required around an elevated
flare. The radius of the area is governed by the heat flux level at maximum (emergency) flaring capacity,
which shall not exceed 2000 BTU/h ft2 (6 kW/m2) at the edge of the sterile area.

At normal operating capacity the heat flux area shall not exceed 500 BTU/h/ft2 (1.5 kW/m2) at the edge of
the sterile area.

The minimum sterile area for elevated flares for refineries and petrochemical plant shall be 200 ft (60 m).
Within the sterile area, only equipment and piping directly related to the flare system is allowed, and all
other equipment, piperack, roads, etc., should be outside the sterile area circle.

8.2.3 Ground Flares and Burn Pits

Ground flares shall be located downwind and have a sterile area, whereby the maximum flaring radiation
level shall not exceed 2000 BTU/h ft2 (6.0 kW/m2).

A burn pit shall not exceed an area larger than 10,000 ft2 (1000 m2). There should be a minimum sterile
area radius of 500 ft (150 m) to allow for the disposal of smoke from the burn pit.

8.2.4 Special Requirement for Flare Location in a GOSP Area

The clearances given above are minimum. Actual clear areas shall be assessed on the radiant heat effects
on personnel and adjacent equipment. The following minimum distances shall be used for ground flares in
GOSP areas:

- 1500 ft (450 m) from production oil or gas wells;

- 500 ft (150 m) from pipeways;
- 1500 ft (450 m) from GOSP battery limits;
- 1500 ft (450 m) from public highways;
- 100 ft (30 m) from buried lines.

Minimum distances for burn pit in GOSP areas shall be as follows:

- 1500 ft (450 m) from GOSP battery limit;

- 1500 ft (450 m) from overhead transmission lines;
- 300 ft (90 m) from GOSP ground flares;
- 200 ft (60 m) from ground oil or gas lines;
- 100 ft (30 m) from buried lines.

8.3 GOSP Facilities

All facilities within the battery limits shall be located at a minimum of 1000 ft (300 m) from major
roadways.

8.4 Loading Facilities

8.4.1 Road Tanker Loading Facilities

 GENERAL ENGINEERING SPECIFICATION GES A.01
PLANT LAYOUT AND SPACING Page 21 of 34
Rev 0 1999

Loading facilities for bulk road vehicles shall be located close to the final product tanks at the periphery of
the plant. Vehicles shall not have to pass through process plot areas or tank farms. Consideration shall be
given to the prevention, containment and disposal of spillages.

The loading area shall be fenced with separate gates. Spacing in relation to other facilities shall be in
accordance with Table 1A (B).

8.4.2 Marine Loading Facilities

The design of marine terminals shall be governed by the Institute of Petroleum Refinery Safety Code,
Section 7.2, and specification, GES R.06.

8.5 Tank Farms

8.5.1 General

Tank farms are a group of atmospheric storage tanks handling petroleum stocks, class I, II, III and
unclassified as specified in the I.P. code stated below.

Classification of crude oil and its derivatives are given in I.P. Model Code of Safe Practice part 3, Refining
Safety Code (Section 1.2).

Atmospheric storage tanks are either the floating roof or fixed roof type. Tanks shall be in a bunded area,
so that spillage or a rupture of a tank can be contained and controlled.

8.5.2 Location

Small tank farms shall be located as in Figure 1. This arrangement provides a buffer zone between process
units and public areas. Tanks shall not be located at a higher elevation than the process units, to prevent
spillage flowing into a hazardous area.

Production tanks shall be located in relation to other facilities in accordance with Tables 1A (B) and
Figure 7.

Large tank farms for bulk storage shall be sited (where possible) in a remote location on elevated ground to
help eliminate or reduce amount of pumping equipment required.

8.5.3 Spacing and Layout

(a) Tank farms shall be divided into independent risk areas in order to minimise fire risk. This
restricts the capacity of tanks in one bunded area.

(b) For tank bunded areas, the following requirements apply to tank Classes I, II (2) and III (2).
In accordance with I.P. Model Code of Practice part 3, Refining Safety Code.

The maximum capacity of tanks in one bunded area is limited and shall be restricted as follows:

- Single tank - no restriction.

- A group of floating roof tanks = 750,000 bb1 (120,000 m3)
- A group of fixed roof tanks = 375,000 bb1 (60,000 m3)
- Crude capacity = not more than two tanks with neither having a greater individual
capacity of 375,000 bb1 (60,000 m3).

(c) The net capacity of a bunded area shall equal the capacity of the largest tank plus the cubic space
occupied by the remaining tanks, up to the level of the bund wall.
 GENERAL ENGINEERING SPECIFICATION GES A.01
PLANT LAYOUT AND SPACING Page 22 of 34
Rev 0 1999
This allows for one tank being breached with the remaining tanks undamaged. The height of the
bund wall is determined by the net capacity of the bund, plus a free-board of 1 ft (0.3 m).

It is recommended that when calculating the size of a bunded area, a bund wall height is first
selected.

The maximum height of a bund wall shall not be greater than 6.5 ft (2.0 m), unless a greater height
is approved by the Owner.

The overall size of the bunded area is governed by calculation as above or by spacing limitations
as shown in Figure 6.

Consideration of accessways inside the bunded area should be made when locating tanks within
that area.

The spacing of a group of tanks within a bunded area shall be in accordance with the IP Refining
Safety Code, Section 5. The layout of storage areas in relation to other facilities shall be in
accordance with Tables 1A (B), and Figures 6 and 7.

When full containment cannot be met by a bunded area, an impounding basin may be used, see
Figure 9. One basin can serve up to 10 tanks or a total capacity of 6.3MM bb1 (1,000,000 m3).
The capacity of the basin together with the tank enclosure, should not be less than the capacity of
the largest tank served. The surface area of the basin shall be limited to 100,000 ft2 (9,000m2) to
facilitate fire fighting. Consideration should be given by the Vendor/Contractor to the economics
of the cost of civil works in this type of installation.

8.6 Pressurised Storage

8.6.1 General

Pressurised LPG is normally stored in spheres or bullets. The following paragraphs provides the
requirements for layout and spacing for spheres and bullets. This specification does not cover semi-
refrigerated storage.

8.6.2 Location

Spheres or bullets shall be located downwind from process areas, administration buildings and workshops,
or residential areas. Location in relation to process units and other facilities shall be in accordance with
Figure 8. Reference shall also be made to the Institute of Petroleum (IP) Model Code of Safe Practice Part
9, and to the LP Gas Association LPG Codes of Practice No 1, Part 1.

If there is any apparent conflict of information from the above codes and guidelines, the IP Code Part 9
shall be the governing criterion.

The location of pressurised storage areas shall provide easy accessibility for fire-fighting.
 GENERAL ENGINEERING SPECIFICATION GES A.01
PLANT LAYOUT AND SPACING Page 23 of 34
Rev 0 1999
8.6.3 Layout and Spacing

(a) Spheres

Spheres should always be located in one row. The maximum number of spheres in one group or
row shall be 6. Any one group shall be separated from another by a distance of 50 ft (15 m).

The minimum distance between spheres shall be 1 x diameter of the larger sphere, with a
minimum of 8 ft (2.5 m) and a maximum of 30 ft (9 m).

The sphere storage area shall be paved and provided with low walls with a maximum height of 2 ft
(600 mm) on three sides, and shall slope toward a collection gutter of approximately 35 ft3 (10 m3)
capacity.

(b) Bullets

Bullets, either earth mounded or aboveground, shall be located side by side at a minimum
separation distance of 5 ft (1.5 m) or 0.25 times the sum of the adjacent vessel diameters,
whichever is the greater. Bullets shall not face spheres, process plants, control rooms etc., in case
of an explosion, when the head of the bullet could act as a projectile.

8.7 Oily Water Separators and Skimming Ponds

Separators and ponds shall be located a minimum of 150 ft (45 m) from process operating areas and other
sources of ignition. These facilities shall be located downwind to avoid vapours or bad odours affecting
the plant. Equipment directly associated with oily water separators shall be spaced for ease of maintenance
and operating access.

S:NOC9077\ADMIN\SPECIFICATIONS\A-SERIES\A-01\GESA01RF
 Administration Building NOTES
NM Warehouses, Buildings Etc 1. HORIZONTAL DISTANCES ARE IN FEET.
NM NM Main Substation 2. MINIMUM HORIZONTAL DISTANCES SHOWN APPLY TO
NM 50 100 Fire Pumps, Fire Station EDGE-TO-EDGE DIMENSIONS.
NM NM NM NM Property Boundary
200 200 200 150 100 Tank Truck Loading LEGEND
100 100 NM NM 100 200 Boilers, Air Compressors NA = NOT APPLICABLE
100 100 200 100 100 150 100 Cooling Towers NO MEASURABLE DISTANCE CAN BE DETERMINED.
NA NA 100 NA 100 200 100 100 Main Control Building

GENERAL ENGINEERING SPECIFICATION

NA NA 100 NA 100 200 100 50 NA Process Unit Control Bldg. NM = NO MINIMUM SPACING REQUIREMENTS ESTABLISHED.
200 200 200 200 200 150 100 100 NA NM Process Unit Battery Limit USE ENGINEERING JUDGEMENT FOR SPACING
NA NA NA NA NA 3 NM NA NM NM NM Unit Isolation, Snuffing Stm.

PLANT LAYOUT AND SPACING

50 50 50 NM NM 50 50 50 50 50 NM NA Hydrants & Fire Monitors EXAMPLE
NA NA NA NA NA 50 NM 50 NM NM NM NA NA Emergency Shutdown DISTANCE BETWEEN PROCESS UNIT FIRED HEATERS AND
NA NM NM NM NM 150 NM 50 NM NM NM NA 50 NA Process Unit Substation PROCESS PUMPS (BELOW AUTO IGNITION) = 50 FEET.
NA NA NA NA NA 50 NA NM NM NM NM NM NM NM NM Electrical Switch Racks (Explosion Proof)
250 250 200 200 200 200 100 100 100 50 NA 50 50 50 50 50 Process Unit Fired Heaters
200 200 200 200 200 200 100 100 100 50 NA 30 50 50 50 50 50 Gas Compressors, Expander
200 200 200 200 200 200 100 100 100 50 NA 30 50 50 50 NM 50 30 Desalters
200 200 200 200 200 200 100 100 100 50 NA 30 50 50 50 50 NM 30 50 Internal Insulated Reactor (above auto ignition)
200 200 200 200 200 200 100 100 100 50 NA 30 50 50 50 20 NM 30 25 25 External Insulated Reactor (above auto ignition)
200 200 200 200 200 200 100 100 100 50 NA 30 50 50 50 20 50 30 25 5 15 Reactors (below auto ignition)
200 200 200 200 200 200 100 100 100 50 NA 50 50 50 50 20 NM 30 25 25 15 15 Exchangers (above auto ignition - 500 deg F)
200 200 200 200 200 200 100 100 100 50 NA 30 50 30 50 20 50 30 10 25 15 15 15 Exchangers (below auto ignition)
200 200 200 200 200 200 100 100 100 50 NA 30 50 50 50 20 10 25 25 25 15 15 15 15 Process Pumps (above auto ignition - 500 deg F)
150 150 200 200 200 100 100 100 100 50 NA 30 50 30 50 20 50 25 15 25 15 15 15 10 5 Process Pumps (below auto ignition)
200 200 250 200 200 200 100 100 100 50 NA 30 50 50 50 20 50 30 15 25 15 15 15 10 15 10 Towers, Drums, Etc.
200 200 150 200 200 150 50 50 25 10 NA NA 50 NA 25 NA 25 15 25 25 15 15 15 10 15 10 10 Process Area Piperack
100 50 50 30 30 50 50 30 30 30 NM NA 15 NA 15 NA 50 30 50 50 50 50 25 15 30 15 30 NM Main Pipeways
200 200 200 200 200 200 100 100 100 50 NA 30 50 NM 50 20 50 25 25 15 15 15 15 10 15 10 10 NM NM Air Coolers
S:\A-SERIES\A-01\DA0110R0.XLS

NM NM NM NM NM 50 NM 50 NM NM NA NA 50 NA NA 15 15 25 NM 15 10 10 10 10 5 5 5 5 NM NM Equipt handling non flammables

GES A.01
Rev 0 1999
Page 33 of 34
250 200 200 100 100 150 200 100 200 200 200 100 SEE NFPA 30 200 200 200 200 200 200 200 200 200 200 200 200 50 200 25 Atmospheric Storage Tanks

TABLE 1A MINIMUM SPACING FOR REFINERIES, CHEMICAL PLANTS AND OIL/GAS FACILITIES (FPS UNITS)
 Administration Building NOTES
NM Warehouses, Buildings Etc 1. HORIZONTAL DISTANCES ARE IN METRES.
NM NM Main Substation 2. MINIMUM HORIZONTAL DISTANCES SHOWN APPLY TO
NM 15 30 Fire Pumps, Fire Station EDGE-TO-EDGE DIMENSIONS.
NM NM NM NM Property Boundary
60 60 60 45 30 Tank Truck Loading LEGEND
30 30 NM NM 30 60 Boilers, Air Compressors NA = NOT APPLICABLE
30 30 60 30 30 45 30 Cooling Towers NO MEASURABLE DISTANCE CAN BE DETERMINED.
NA NA 30 NA 30 60 30 30 Main Control Building

GENERAL ENGINEERING SPECIFICATION

NA NA 30 NA 30 60 30 15 NA Process Unit Control Bldg. NM = NO MINIMUM SPACING REQUIREMENTS ESTABLISHED.
60 NA 60 60 60 45 30 30 NA NM Process Unit Battery Limit USE ENGINEERING JUDGEMENT FOR SPACING
NA NA NA NA NA 0.9 NM NA NM NM NM Unit Isolation, Snuffing Stm.

PLANT LAYOUT AND SPACING

15 15 15 NM NM 15 15 15 15 15 NM NA Hydrants & Fire Monitors EXAMPLE
NA NA NA NA NA 15 NM 15 NM NM NM NA NA Emergency Shutdown DISTANCE BETWEEN PROCESS UNIT FIRED HEATERS AND
NA NM NM NM NM 45 NM 15 NM NM NM NA 15 NA Process Unit Substation PROCESS PUMPS (BELOW AUTO IGNITION) = 15 METRES
NA NA NA NA NA 15 NA NM NM NM NM NM NM NM NM Electrical Switch Racks (Explosion Proof)
75 75 60 60 60 60 30 30 30 15 NA 15 15 15 15 15 Process Unit Fired Heaters
60 60 60 60 60 60 30 30 30 15 NA 9 15 15 15 15 15 Gas Compressors, Expander
60 60 60 60 60 60 30 30 30 15 NA 9 15 15 15 NM 15 9 Desalters
60 60 60 60 60 60 30 30 30 15 NA 9 15 15 15 15 NM 9 15 Internal Insulated Reactor (above auto ignition)
60 60 60 60 60 60 30 30 30 15 NA 9 15 15 15 6 NM 9 7.5 7.5 External Insulated Reactor (above auto ignition)
60 60 60 60 60 60 30 30 30 15 NA 9 15 15 15 6 15 9 7.5 1.5 4.5 Reactors (below auto ignition)
60 60 60 60 60 60 30 30 30 15 NA 15 15 15 15 6 NM 9 7.5 7.5 4.5 4.5 Exchangers above auto ignition - 500 deg F(260deg C)
60 60 60 60 60 60 30 30 30 15 NA 9 15 9 15 6 15 9 3 7.5 4.5 4.5 4.5 Exchangers (below auto ignition)
60 60 60 60 60 60 30 30 30 15 NA 9 15 15 15 6 3 7.5 7.5 7.5 4.5 4.5 4.5 4.5 Process Pumps above auto ignition - 500 deg F(260deg C)
45 45 60 60 60 30 30 30 30 15 NA 9 15 9 15 6 15 7.5 4.5 7.5 4.5 4.5 4.5 3 1.5 Process Pumps (below auto ignition)
60 60 75 60 60 60 30 30 30 15 NA 9 15 15 15 6 15 9 4.5 7.5 4.5 4.5 4.5 3 4.5 3 Towers, Drums, Etc.
60 60 45 60 60 45 15 15 7.5 3 NA NA 15 NA 7.5 NA 7.5 4.5 7.5 7.5 4.5 4.5 4.5 3 4.5 3 3 Process Area Piperack
30 15 15 9 9 15 15 9 9 9 NM NA 4.5 NA 4.5 NA 15 9 15 15 15 15 7.5 4.5 9 4.5 9 NM Main Pipeways
60 60 60 60 60 60 30 30 30 15 NA 9 15 NM 15 6 15 7.5 7.5 4.5 4.5 4.5 4.5 3 4.5 3 3 NM NM Air Coolers
S:\A-SERIES\A-01\DA0110R0.XLS

NM NM NM NM NM 15 NM 15 NM NM NA NA 15 NA NA 4.5 4.5 7.5 NM 4.5 3 3 3 3 1.5 1.5 1.5 1.5 NM NM Equipt handling non flammables

GES A.01
Rev 0 1999
Page 34 of 34
75 60 60 30 30 45 60 30 60 60 60 30 SEE NFPA 30 60 60 60 60 60 60 60 60 60 60 60 60 15 60 7.5 Atmospheric Storage Tanks

TABLE 1B MINIMUM SPACING FOR REFINERIES, CHEMICAL PLANTS AND OIL/GAS FACILITIES (METRIC UNITS)
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.01

PROTECTION OF MATERIALS AND EQUIPMENT

DURING STORAGE

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES C.01
PROTECTION OF MATERIALS AND EQUIPMENT Page 2 of 14
DURING STORAGE Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Other NOC Specifications 3

2.0 DEFINITIONS 3

2.1 Technical 3
2.2 Contractual Terms 4

3.0 BASIC PRINCIPLES OF PRESERVATION 5

4.0 PRESERVATION OF LARGE ASSEMBLIES 6

4.1 Types of Assemblies 6

4.2 Preparation for Preservation 6
4.3 Protective Packing 7
4.4 Periodical Checking 7

5.0 PRESERVATION OF SMALL ASSEMBLIES 9

5.1 Types of Assemblies 9

5.2 Preparation for Preservation 9
5.3 Protective Packing 10
5.4 Periodical Checking 10

6.0 PRESERVATION OF VALVES 11

6.1 Types of Valves 11

6.2 Preparation for Preservation 11
6.3 Protective Packing 11
6.4 Periodical Checking 12

7.0 PRESERVATION OF SMALL ITEMS 12

7.1 Types of Assemblies 12

7.2 Preparation for Preservation 12
7.3 Protective Packing 12
7.4 Periodical Checking 13

8.0 PRESERVATION OF OTHER ITEMS 13

8.1 Types of Items 13

8.2 Preparation for Preservation 14
8.3 Protective Packaging 14
8.4 Periodical Checking 14
 GENERAL ENGINEERING SPECIFICATION GES C.01
PROTECTION OF MATERIALS AND EQUIPMENT Page 3 of 14
DURING STORAGE Rev 0 1999

1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification applies to equipment and materials used in refineries, onshore oil and gas
installations and processing facilities which are to be stored and preserved specifically to maintain the
mechanical integrity and functionality in respect to their end-use.

The various procedures included here are meant to protect the items against degradation,
disintegration, and premature ageing due to the various adversaries such as the weather, lack of care,
mishandling etc.

1.1.2 The specification will also govern the storage and upkeep of all the spare parts, replenishing
chemicals and utilities.

1.1.3 Proper storage and periodic inspection of the inventory results in:

- quality assurance and readiness of equipment and materials for their safe use;
- improved plant/equipment operability;
- decreased overall production costs.

1.1.4 The reduction in overall running costs is derived from the superior life in operation of spare parts,
equipment and materials that have been correctly preserved, over those that have been allowed to
deteriorate in some manner.

1.1.5 The added assurance of being able to maintain operations comes from the confidence and real
benefits that materials, equipment, and components held in inventory, will be suitable for use when
required. Where preservation is inadequate then the life of the retained item will be reduced or, in the
worst case, will not be suitable at all.

1.2 Other NOC Specifications

1.2.1 Where indicated in this specification the latest edition of the following additional NOC Specification
shall apply:

GES C.02 Protection of Materials and Equipment during Construction

2.0 DEFINITIONS

2.1 Technical

2.1.1 The technical terms referred to within this specification are defined as follows:

Contamination

This is any extraneous materials that will give rise to damage, deterioration, or corrosion. This may be
products originated within the plant itself, e.g. acidic vapours, or natural elements such as sand and
humidity.

Corrosion

Corrosion is the deterioration through the gradual eating away of a material through the attack of
liquids and gases to which it is exposed. The rate of corrosion is affected to a considerable extent by
 GENERAL ENGINEERING SPECIFICATION GES C.01
PROTECTION OF MATERIALS AND EQUIPMENT Page 4 of 14
DURING STORAGE Rev 0 1999

the conditions of exposure, the type of corrosive medium, the nature of the products of corrosion and
by the presence of certain bacteria or marine growths.. This is a very basic interpretation as many
other influencing factors determine the rate or ability of one substance to corrode another. The most
common is the corrosion attack on bare steel by moisture which may be accelerated by the presence
of other organic and inorganic compounds.

Damage

Any physical impact upon a material or item of equipment that in any way impairs the performance or
the physical features of the material or equipment.

Deterioration

Deterioration is a condition that adversely affects the properties (physical or chemical) or

performance of the item under consideration.

Original Equipment Manufacturer (OEM)

This is the organization who originally manufactured the equipment or material supplied to the
Owner. This may not necessarily have been the original supplier. Normally, only the OEM has the
details necessary to ensure that any preservation they recommend will not in any way effect, in a
detrimental manner, the item itself.

Vapour Phase Inhibitors (VPIs) and Preservatives

These are materials that serve as a barrier between the material and the attacking agent either as a mist
(vapour) or as a viscous liquid, that settles out onto the surfaces to be protected or as a positive barrier
applied thick enough to prevent the penetration of the attacking agent over a period of time. These
materials can provide protection up to a maximum specified time period, after which time they must
be replaced. Caution must be exercised in the selection of these materials as they themselves may, in
certain circumstances and on certain materials, act as the corroding agent.

2.2 Contractual Terms

The commercial terms used within this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and
facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority
 GENERAL ENGINEERING SPECIFICATION GES C.01
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The organization representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements
of this specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verifies that the equipment and facilities have been designed, constructed, inspected
and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 BASIC PRINCIPLES OF PRESERVATION

3.1 In order to ensure that preservation of an item is both economically and technically viable, it is
necessary to take into consideration the following two (2) factors:-

- the length of time the preservation must be maintained;

- factors affecting corrosion/degradation.

3.2 The details given in this specification are intended to be of a general nature and it must be
remembered that each case, where preservation is to be considered, has its own unique problems
which must be resolved through the application of common sense and, more particularly, the
recommendations of the OEM.

3.3 Even if the requirements of this specification and recommendations of the OEM are followed in the
initial preservation for storage, the preservation technique used will require some routine re-validation
to ensure preservation integrity. After initial preservation, an item is not completely safe from
degradation. It must be checked periodically to ensure integrity is maintained of the preservation
media used in the storage conditions.

3.4 Storage time is classified into three levels:

- short term or temporary, i.e. normally the time defined for the period between the
manufacture and the installation of new equipment and material which will not be part of
sustainable inventory, or items which will be consumed within six (6) months or less after
being received on site;

- medium, i.e, the time period determined for the protection and preservation of items which
are classed as consumable in nature, many of which will have a limited shelf life only, and
are maintained on a stock rotation basis. This is limited to eighteen (18) months after which
time the items must be subjected to formal re-evaluation and, if necessary, reclassification
for long term storage or re-introduction to a second medium term storage cycle;

- long term, i.e. when it is anticipated that the component must remain available, for use in the
event of breakdowns or as replacement through wear and tear, for an undefined time period.

3.5 The storage environment is an essential part of the overall preservation activities necessary to
maintain the overall integrity of inventory. In many instances the actual storage environment e.g.
outdoors in the open, may provide a negative impact on the preservation of the product.

3.6 Proper and correct identification of items and assemblies is paramount at all times. Identification
marks, tags/labels should have all necessary part numbers, equipment numbers etc. for easy
traceability.
 GENERAL ENGINEERING SPECIFICATION GES C.01
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4.0 PRESERVATION OF LARGE ASSEMBLIES

4.1 Types of Assemblies

4.1.1 This category of equipment includes all complete assemblies having at least one dimension greater
than 20 in (0.5 m) and comprises numerous component parts that are subject to corrosion or
deterioration.

4.1.2 Typical items include, motors, pumps, compressors, electric motors, heat exchangers, air
conditioners, blowers, fans, gear boxes, turbines, expanders, electrical distribution panels,
transformers, generators, rotor assemblies, screw feeders, mills, mixers, filters and other large
mechanical devices.

4.1.3 Valves are not included in this category.

4.2 Preparation for Preservation

4.2.1 The assembly may be received in a state suitable for long term preservation dependant upon the
Purchase Order/Contract under which it was purchased. An examination shall be conducted to
determine if there is in place suitable preservation meeting the requirements of this specification, or if
there is any damage or deterioration already existing.

4.2.2 Disconnect any batteries and drain free of electrolyte. Any fragile items that may be easily damaged,
such as sight glasses shall either be fully protected against damage or removed. Seal all openings with
correctly fitting plugs to eliminate any ingress of water or sand or any other extraneous materials. The
removed items shall be correctly prepared for storage and packed in accordance with the appropriate
sections of this specification. These items shall be firmly affixed to the unit or its skid base and clearly
identified on the packaging with clear reference to the contents.

4.2.3 All grease points shall be packed with grease, oil sumps drained and replaced with anti-corrosion oil,
fuel tanks and other liquid lines drained and sprayed internally with an anti-corrosion mist (vapour
phase inhibitor) unless this is contrary to the instructions of the OEM. Vapour phase inhibitors shall
not be used on aluminium, cadmium, or zinc (including galvanized products) in a confined space as
there may be a danger of the generation of flammable gas.

4.2.4 All external orifices shall be plugged and taped to ensure a water/dust proof seal is obtained. All
temporary restraining devices shall be installed in accordance with the instructions of the OEM and
details added in large lettering on a red or fluorescent label to ensure its removal before starting or
recommissioning.

4.2.5 All machined and unpainted surfaces shall be treated with a suitable corrosion inhibiting fluid
dependant upon the anticipated storage time, or wrapped in waterproof self-sealing linen.

4.2.6 All instrument air lines shall be maintained clean and dry and, where practical, purged or swept,
slightly pressurised with nitrogen before sealing with air tight plugs. This will prevent seepage of air
into tubes/pipes. A cautionary note shall be posted at appropriate locations to make personnel aware
that the instrument lines are pressurised.

4.3 Protective Packing

4.3.1 All equipment shall be mounted onto a base or pallet and secured to prevent movement. It shall be
 GENERAL ENGINEERING SPECIFICATION GES C.01
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determined which of the following preservation coverings shall be used as a method of protection:

- protection by tarpaulin;
- protection by a thermoweldable aluminium - polyethylene envelope containing a desiccant
material (silica gel);
- protection by the use of a complete packing case.

4.3.2 If the item is to be covered by tarpaulin, checks shall be made to ensure any delicate items are firmly
supported and secured. Where necessary they shall be removed and separately packed and then
secured to the skid, or wired onto the unit. Supporting timbers shall also be used to ensure there is an
air gap between the tarpaulin and the unit. The tarpaulin is then placed over the unit and firmly fixed
by ropes or other means to prevent it from being blown off by the wind. The covered unit may then
remain where it is or be moved under shelter.

4.3.3 If it is determined to protect the unit by the use of thermoweldable aluminium-polyethylene then this
shall be performed by first laying the sheet onto the skid and then fixing the unit itself to the skid.
The unit shall be checked for sharp protrusions that may puncture the envelope when it is complete.
Where necessary, the protruding part shall be removed and fixed elsewhere onto the skid, or wrapped
in cloth or polyethylene to form a protection from puncturing. Bags of silica gel shall then be
suspended from the unit or placed on the skid away from the unit. These bags shall not be brought
into direct contact with the unit itself as this may provide a high local concentration of moisture which
could cause local corrosion. The thermoweldable aluminium-polyethylene sheet shall then be drawn
up around the unit to form an envelope. Any surplus material shall then be cut away before forming a
complete seal by thermowelding the edges in accordance with the aluminium-polyethylene sheet
manufacturers instructions.

4.3.4 Sensitive equipment items, such as gas turbines shall be protected to a greater degree for long term
preservation. After carrying out normal sealing and inhibiting the unit may then be protected by a
thermoweldable aluminium-polyethylene envelope but mounted onto the base of a packing case
instead of a skid. The base, sides and top of the packing case shall be lined with tarred paper to
prevent ingress of sand. Access doors may be fitted to the case to enable routine inspections to be
carried out. If the case is not going to be stored under a rain shelter then the top of the case shall be
covered by a tarpaulin or plastic to prevent ingress of rain. Full details of the contents of the case shall
be clearly marked on both long sides of the case.

4.3.5 As an alternative the preserved unit may be placed in a standard sealed sea transport container.

4.4 Periodical Checking

4.4.1 A formal verification schedule (see Table 1) shall be set up to ensure all machinery is checked at least
once per year depending upon the level of preservation technique applied. If the unit has been set up
initially for long term, deep storage then this may be extended to eighteen (18) months. An inspection
of the external condition shall be carried out every six (6) months and if any problem or suspected
damage occurs then the unit shall be examined as defined in this section.
 GENERAL ENGINEERING SPECIFICATION GES C.01
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TABLE 1: Periodical Inspection Requirements

Storage Period Inspection Action to be carried out

Frequency

Short term Upon Receipt Normal receiving inspection to be carried out. Items to be
returned to packaging or moved to warehouse location.
6 Months Evaluate if a longer term preservation will be required if items
are not going to be used within one month. Reclassify if
required.

Medium Term Upon Receipt Normally receiving inspection to be carried out and confirm
the items are adequately preserved for medium term storage.
If not, carry out preservation in accordance with this
specification. Re-package items in original packing or repack
according to this specification. Replace any desiccant and
ensure any nitrogen charge is at correct pressure.
6 Months Check packing. If applicable and accessible, replace any
desiccant and ensure any nitrogen charge is at correct
pressure. If any evidence of degradation fully unpack, inspect
and re-preserve as necessary.
Annual Unpack item and inspect. Rotate all shafts to ensure free
bearing movement. Re-preserve and re-pack as necessary to
maintain the preservation integrity. For bulk items such as
valves, open at least one package for each make, size and
type.
18 Months Re-assess storage requirement and reclassify if required.

Long Term Upon Receipt Unpack and conduct receiving inspection. Ensure
preservation is suitable for long term and if not preserve as
defined in this procedure. Replace desiccant and recharge
nitrogen where applicable. Re-package in accordance with
this specification.
6 Months Check packing. If applicable and accessible, replace any
desiccant and ensure nitrogen charge is at correct pressure.
Annual Unpack item and inspect. Rotate all shafts to ensure free
bearing movement. Re-preserve and re-pack as necessary to
maintain the preservation integrity. For bulk items such as
valves, open at least one package for each make, size and
type.
3 Years Unpack item and remove all preservatives. All machinery is
to be given a trial run or rotation to ensure continued
suitability for use. All other equipment is to be examined to
confirm its continued suitability for use. Re-assess storage
requirements and re-preserve in accordance with this
specification to the level required top meet the new storage
life.

4.4.2 Every six (6) months the packaging shall be checked for evidence of damage or deterioration. Where
access is available, desiccant bags shall be changed and nitrogen recharged. Any evidence of damage,
 GENERAL ENGINEERING SPECIFICATION GES C.01
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significant ingress of sand or water, or any deterioration to the packaging shall be reported to the
Maintenance Department who will determine a suitable course of action.

4.4.3 On an annual basis, or in the event of reported damage, or on the extended scheduled inspection date,
the unit shall be examined for signs of deterioration. The packaging shall be opened in order to verify
the internal condition.

4.4.4 All equipment with crankshafts, axles or other rotating parts shall be mechanically operated to ensure
there is no seizure of shafts and other moving parts. This is especially important for pumps with large
overhung impellers that can impose very uneven loads onto bearings in the static position, and that
may lead to out of balance conditions due to the bending moment on the shaft.

4.4.5 All desiccant (silica gel) bags shall be replaced at each inspection. All visible surfaces are to be
checked for signs of corrosion and/or damage. All surfaces coated with preservative shall be cleaned
and new preservative fluids applied. Vapour phase inhibitors shall be re-applied to internal areas and
any nitrogen purges recharged.

4.4.6 All engines shall be checked by preparing them for running and then conducting a short run to verify
they are still fully functional. This is at the option of the Maintenance Supervisor in conjunction with
manufacturers guidelines, but in no case shall an engine be left for more than 3 years without either a
trial run or rotation. For other rotating equipment trial rotation shall be carried out to ensure the
freedom of all moving parts at low speed. After running they shall be re-preserved as defined in this
specification.

4.4.7 Sensitive equipment items, such as gas turbines, when intended for extended storage, shall be
provided with manual and/or electric barring system to facilitate periodic rotor rotation (at very low
RPM). This function shall be carried out with simultaneous operation of either DC or AC lube oil
pump.

4.4.8 Rotors and/or rotor assembly for heavy rotating equipment shall be provided with temporary pedestal
bearing during storage to facilitate rotation for preventing out of balance condition occuring as a
result of high bending moment imposed on the shaft.

5.0 PRESERVATION OF SMALL ASSEMBLIES

5.1 Types of Assemblies

5.1.1 This applies to small complete assemblies with all dimensions smaller than 20 in (0.5 m) with
surfaces subject to oxidation and with rubber, teflon, composite or carbon components subject to
decay.

5.1.2 Typical items are small electric motors, pumps, portable lighting generators, actuators,electronic
governors, valves (less than 4 in NPS), small electrical and electronic equipment such as electric
meters, printed circuit boards, solenoids, relays, circuit breakers,chargers, etc.

5.2 Preparation for Preservation

5.2.1 Vacuum clean or clean using compressed air to remove any dirt and dust. Confirm all openings are
sealed to prevent ingress of moisture, dust and sand. All machined surfaces shall then be sprayed
with a corrosion preventive fluid suitable for the determined storage time or wrapped in waterproof
linen.
5.2.2 All loose items shall be secured in a plastic bag and wired onto the unit so they remain together with
the unit. These shall also be sprayed with preservative if containing corrodible materials.
 GENERAL ENGINEERING SPECIFICATION GES C.01
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5.3 Protective Packing

5.3.1 The degree of packing will depend upon the nature of the item, and will normally be selected from
one of these options:

- pack in special container;

- wrap in plastic film or thermoweldable aluminium-polyethylene envelope;
- no further packaging.

5.3.2 The preserved units may be returned to their original packaging when they were initially supplied.
This is the preferred option as often the manufacturer will have designed special protective packaging
for shipment of particular instruments. Any desiccant bags included within the original packaging
shall be replaced. Electronic circuit boards shall be placed inside anti-static bags before placing them
into their final packaging. All packages, boxes, etc, shall be clearly marked with details of part
number, stock number, description and any other identifying references on at least two sides of the
package.

5.3.3 Preserved units may then be encased in a thermoweldable aluminium-polyethylene envelope or

plastic bag. Desiccant shall be added, however, it must not be allowed to come in direct contact with
the item itself. Clear details of the contents, part numbers, stock numbers and any other identifiers
must be marked onto a label and/or on the packaging itself using an indelible marker. The label shall
be firmly affixed to the package.

5.3.4 Preserved units that are not delicate in nature, such as small valves that have been adequately
protected with preservatives and all openings sealed, shall be identified with a label, using an
indelible marker, showing the stock number, part number and any other required identifiers.

5.3.5 All items prepared under this section of the specification shall be held in a warehouse environment.
Where appropriate, the items will be set onto pallets for storage, placed in storage bins or direct onto
storage shelves. In the event that these items must be put into open storage then they shall be formally
packed as defined in Section 4 of this specification.

5.4 Periodical Checking

5.4.1 At least every six (6) months the packaging shall be examined for damage or deterioration. Items that
have not been packaged shall be checked for signs of corrosion or damage to protective coatings. If
there is any sign of damage or deterioration then the units shall be fully examined and protective
treatment re-applied.

5.4.2. On an annual basis packaged units shall be checked by selecting one package at random from the
stock and opening it to verify the condition of contents. If the contents are satisfactory then the unit is
repacked and returned to stock.

5.4.3 All items that are not packaged shall be checked on an annual basis and the protective preservation
materials re-applied. This can be extended to eighteen (18) months at the option of the Maintenance
Supervisor.

5.4.4 Small shaft assembly items, i.e. motors and pumps shall have their shafts hand rotated every six (6)
months to ensure no damage occurs to the bearings in the assembly.

6.0 PRESERVATION OF VALVES

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6.1 Types of Valves

6.1.1 This applies to valves 4 in NPS and larger of all types, e.g. ball, gate, globe, plug, control, check
valves etc.

6.1.2 Typically valves will be either hand wheel operated, fitted with an actuator, or supplied with bare
stem.

6.2 Preparation for Preservation

6.2.1 Clean the valve using compressed air to remove any dirt and dust. Confirm all ball and plug valves
are in the open position. Confirm all gate, check, and butterfly valves are in the closed position. For
special types of valves and non-ferrous, refer to manufacturers recommendations. For ferrous valves
heavy duty grease shall be applied to all working parts of the valves. All other machined surfaces
shall then be sprayed with a corrosion preventive fluid suitable for the determined storage time or
wrapped in waterproof linen.

6.2.2 All flanges shall be fitted with wooden or plastic flange protectors. Any desiccant used for preserving
the inner surfaces shall not be placed directly in contact with the valve surface but shall be fixed onto
the inside of the flange protector. Once the flange protectors are fitted then they shall be taped to seal
the valves from ingress of water, sand or other extraneous materials.

6.2.3 All loose items shall be secured in a plastic bag and wired onto the valve so they remain together with
the valve. These shall also be sprayed with preservative if containing corrodible materials.

6.2.4 Any actuator fitted to the valve shall be completely wrapped in polyethylene of a type with ultraviolet
resistance or, preferably encased in a weldable aluminium-polyethylene envelope. Any delicate items
such as gauges must be protected with heavy duty cardboard or additional wrapping to protect from
damage. Desiccant may be added within the packaging providing it is not in contact with the actuator
itself.

6.3 Protective Packing

6.3.1 The degree of packing will depend upon the nature and size of the valve, and will normally be
selected from one of these options:

- protection by tarpaulin;
- protection by formal packing case;
- no further packaging.

6.3.2 If the preserved valves are to be stored outside, then they shall be covered by tarpaulin as defined in
Section 4.0 of this specification.

6.3.3 Preserved valves may be encased in a formal packing case as defined in Section 4.0 of this
specification or returned to the original manufacturers packaging if available and in good condition.
Clear details of the contents, part numbers, stock numbers and any other identifiers shall be marked
onto the packing case with a permanent marker.

6.3.4 Valves that can be stored in a warehouse and that have been adequately protected with preservatives
and all openings sealed, are to be identified using a label, with a permanent marker, showing the stock
number, part number and any other required identifiers. No further packaging is required.

6.4 Periodical Checking

 GENERAL ENGINEERING SPECIFICATION GES C.01
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6.4.1 At least every six (6) months the packaging shall be examined for damage or deterioration. Items that
have not been packaged shall be checked for signs of corrosion or damage to protective coatings. If
there is any sign of damage or deterioration then the units shall be fully examined and protective
treatment re-applied.

6.4.2. On an annual basis packaged units shall be checked by selecting one package at random from the
stock and opening it to verify the condition of contents. If the contents are satisfactory then the unit
shall be repacked and returned to stock.

6.4.3 All valves that are not packaged shall be checked on an annual basis and the protective preservation
materials re-applied. This can be extended to eighteen (18) months at the option of the Maintenance
Supervisor.

7.0 PRESERVATION OF SMALL ITEMS

7.1 Types of Assemblies

7.1.1 This applies to small items that can fail to function if allowed to deteriorate by relatively small
amounts including items both with oxydizable surfaces and/or rubber, teflon, composite or carbon
components subject to decay.

7.1.2 Typical items are all types of bearings, mechanical carbon seals, special seals, rotating wear rings,
ceramic seals bushings, joint rings, gaskets, “O” rings, “V” belts, flexible couplings, rubber joints,
electrical isolators, flexible hose, expansion joints, etc.

7.2 Preparation for Preservation

7.2.1 Vacuum clean or clean using compressed air to remove any dirt and dust. All machined surfaces shall
then be sprayed with a corrosion preventive fluid suitable for the determined storage time or wrapped
in waterproof linen or dipped in a proprietary wax coating type preservative.

7.2.2 All rubber components, both natural and synthetic types, shall be lightly dusted with talcum powder
and placed inside black bags or returned to their original packaging providing it will provide
protection from light. Where practical “O” rings and “V” belts will be retained in the fully formed
position and supported on card or plyboard. Avoid twisting out of their preformed shape.

7.2.3 All gaskets, and other composite materials shall be checked for damage and deterioration and then
prepared for storage by either returning to the existing packaging or placing flat onto card and shrink
wrapping.

7.3 Protective Packing

7.3.1 The degree of packing will depend upon the nature of the item, and will normally be selected from
one of these options:

- retain in original packaging;

- shrink wrap or wrap in waterproof linen;
- pack in special containers or boxes;
- dip in wax type preservative.

7.3.2 The preserved units may be returned to their original packaging when they were initially supplied.
This is the preferred option as often the manufacturer will have designed special protective packaging
 GENERAL ENGINEERING SPECIFICATION GES C.01
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for shipment, in particular bearings and seals. Items susceptible to deterioration from light exposure
such as natural rubbers shall also be wrapped in lightproof bags before storing. All packages, boxes,
etc, shall be clearly marked with details of part number, stock number, description and any other
identifying references on the package. Storage temperature shall be maintained in line with the
requirements of the part manufacturer.

7.3.3 Preserved units may be then encased in shrink wrapping or waterproof linen. Items may then be
placed in storage bins or boxes. Clear details of the contents, part numbers, stock numbers and any
other identifiers must be marked onto a label using an indelible marker and/or on the packaging
itself. The label shall be firmly affixed to the package.

7.3.4 Preserved units that are delicate in nature and can easily be damaged, shall be formally packaged.
Bubble wrap film, corrugated paper or polyethylene shall be used to wrap the items before packaging
to act as a shock buffer before packing into boxes or direct into storage bins. All items shall be
individually identified with a label, using an indelible marker, showing the stock number, part number
and any other required identifiers.

7.3.5 Bearings and other metallic items shall be preserved by the application of pealable wax coatings.
Items are dipped into the molten wax in accordance with the suppliers instructions and then checked
to ensure the coating is complete. The dipped items shall then be placed in bags or boxes with details
of stock number, part number, and any other identifiers.

7.3.6 All items prepared under this section of the specification shall be held in a formal stores environment,
i.e in an enclosed store. Where appropriate, the items shall be set onto pallets for storage, placed in
storage bins or direct onto storage shelves. In the very unlikely event that these items shall be put into
open storage then they shall be formally packed as defined in Section 4.0 of this specification.

7.4 Periodical Checking

7.4.1 At least every six (6) months the packaging shall be examined for damage or deterioration. Items that
have not been packaged shall be checked for signs of corrosion or damage to protective coatings. If
there is any sign of damage or deterioration then the items shall be fully examined and protective
treatment re-applied

7.4.2. On an annual basis packaged units shall be checked by selecting one package at random from the
stock and opening it to verify the condition of contents. If the contents are satisfactory then the unit
shall be repacked and returned to stock.

7.4.3 All items that are not packaged shall be checked on an annual basis and the protective preservation
materials re-applied. This can be extended to eighteen (18) months at the option of the Maintenance
Supervisor.

8.0 PRESERVATION OF OTHER ITEMS

8.1 Types of Items

8.1.1 This shall include all fasteners, nuts, bolts, washers, screws, fittings, clips, tools, and other bulk
purchased items that are subject to corrosion. In addition this section shall also include items that may
not necessarily corrode but are delicate or fragile, such as light bulbs, electronic components, sight
glasses, laboratory glassware, light fittings, electrical components and all other consumable items.

8.2 Preparation for Preservation

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8.2.1 All metallic components shall be sprayed with either light oil or light preservative fluids unless
already pre-packaged. Any pre-packaged items shall be checked to confirm there is no visible form of
damage or deterioration. If there is any evidence of deterioration, then the package shall be opened
and the contents cleaned and oiled or preserved.

8.2.1 All non-metallic items shall be checked for physical condition and then packaged as necessary to
ensure they remain undamaged. All glass or other delicate items shall be marked as “Fragile”.

8.3 Protective Packaging

8.3.1 All items included under this category do not require specific packaging other than to be stored in a
dry and clean environment. Where practical, the items will remain in their as received packaging.

8.4 Periodical Checking

8.4.1 At least every six (6) months the stock shall be examined for damage or deterioration. Items that have
not been packaged shall be checked with the manufacturers' recommendations and assessed for
damage or deterioration on an annual basis.

8.4.2 On an annual basis packaged items that are subject to corrosion shall be checked by selecting one
package at random from the stock and opening it to verify the condition of contents. If the contents
are satisfactory then the unit shall be repacked and returned to stock.

8.4.3 All items that are not subject to corrosion shall be checked on an annual basis and checked for
damage.

S:\NOC9077\ADMIN\SPECIFICATIONS\C-SERIES\C-01\GESC01RF
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.02

PROTECTION OF MATERIALS AND EQUIPMENT

DURING CONSTRUCTION

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES C.02
PROTECTION OF MATERIALS AND EQUIPMENT Page 2 of 7
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INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Other NOC Specifications 3
1.3 Codes and Standards 3

2.0 DEFINITIONS 3

2.1 Technical 3
2.2 Contractual 4

3.0 ESSENTIALS 5

4.0 PIPELINES AND PRE-FABRICATED PIPEWORK 5

5.0 PRESSURE TESTING 6

6.0 EQUIPMENT 7

7.0 PROTECTIVE COATINGS 7

 GENERAL ENGINEERING SPECIFICATION GES C.02
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification defines the general requirements for the protection of all equipment and materials used
during the construction phase of a project for refineries, on-shore oil and gas installations, and processing
facilities.

1.1.2 Such equipment and materials shall be handled and stored specifically to maintain the mechanical integrity
and functionality in respect to their end use.

1.1.3 The various procedures included in this specification are meant to protect the items against damage and
degradation due to various adversaries such as the weather, lack of care, mishandling, etc.

1.1.4 This specification is not meant to replace or modify the erection and installation procedures, but to
supplement them with details of how to ensure overall integrity of equipment and materials during the
construction phase.

1.2 Other NOC Specifications

1.2.1 Where indicated in this specification, the following additional NOC Specifications shall apply:

GES C.01 Protection of Materials and Equipment during Storage

GES C.03 Safety Procedures on Construction Sites

GES C.05 Mechanical Equipment Installation Practices

GES C.06 Electrical Installation Practices

1.3 Codes and Standards

1.3.1 There are no specific codes and standards identified which are unique to the scope of this specification,
however individual supporting installation and commissioning specifications will identify the appropriate
equipment or material codes which may, or may not, provide details on special protection requirements.

2.0 DEFINITIONS

2.1 Technical

2.1.1 The technical terms referred to within this specification are defined as follows:

Deterioration

Deterioration is a condition that adversely affects the properties (physical or chemical) or performance of
the item under consideration.

Corrosion

Corrosion is the deterioration through the gradual eating away of a material by the attack of liquids and
gases to which it is exposed. The rate of corrosion is affected to a considerable extent by the conditions of
exposure, the type of corrosive medium, the nature of the products of corrosion and by the presence of
certain bacteria or marine growths. This is a very basic interpretation as many other influencing factors
determine the rate or ability of one substance to corrode another. The most common is the corrosion attack
on bare steel by moisture which may be accelerated by the presence of other organic and inorganic
compounds.
 GENERAL ENGINEERING SPECIFICATION GES C.02
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DURING CONSTRUCTION Rev 0 1999

Contamination

This is any extraneous materials that will give rise to damage, deterioration, or corrosion. This may be
products originated within the plant itself, e.g. acidic vapours, or natural elements such as sand and
humidity.

Vapour Phase Inhibitors (VPI’s) and Preservatives

These are materials that serve as a barrier between the material and the attacking agent either as a mist or
vapour that settles out onto the surfaces to be protected or as a positive barrier applied thick enough to
prevent the penetration of the attacking agent over a period of time. These materials can provide protection
up to a maximum specified time period, after which time they must be replaced. Caution must be exercised
in the selection of these materials as they themselves may, in certain circumstances and on certain
materials, act as the corroding agent.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 ESSENTIALS

3.1 No material or equipment shall be issued to the field unless it is due for installation, and arrangements are
complete for the lifting . This reduces the time the materials and equipment are exposed to the possibility of
contamination, and damage.
 GENERAL ENGINEERING SPECIFICATION GES C.02
PROTECTION OF MATERIALS AND EQUIPMENT Page 5 of 7
DURING CONSTRUCTION Rev 0 1999

3.2 All equipment shall be clearly identified in order to ensure it is not accidentally installed in the wrong
location, where it might be subjected to damage or be a safety hazard due to incorrect use. Any item, or
material found without correct identification, shall be classed as non-conforming until its identity can be re-
established. Identification of all items shall be re-affirmed after installation, during pre-commissioning.

3.3 All materials used in construction that can deteriorate, such as cement, shall be issued from its storage area
in only sufficient quantities to complete the task at hand. If large quantities are issued then the surplus from
an operation must be returned to the storage area where it can undergo any necessary preservation to
prevent its further degradation.

3.4 All equipment items shall remain in their storage packaging until they are ready for use. All openings shall
remain sealed and any openings that are made for inspection purposes shall be resealed until the equipment
is ready for installation to prevent ingress of foreign materials, e.g. water, refuse, sand, etc.

3.5 Any item removed for testing purposes, e.g. instruments, valves, gauges, etc. shall be positively identified
to the unit they were removed from. All resulting openings shall be sealed to prevent ingress of foreign
materials and the removed item shall be subjected to preservation, i.e. temporary packaging, greasing,
covering, etc.

3.6 All bracing, temporary supports, rotor locking devices, etc., shall remain in place until the equipment is
ready to be commissioned. In all cases equipment must be retained in a protected condition until the last
moment to avoid unnecessary damage.

3.7 Consideration shall be given to the application of temporary preservatives during the construction on items
where there will be some time lag between installation and commissioning. As an example, all anchor bolts
must be protected by grease, or proprietary preservatives, from the time of installation until they are used to
bolt down the actual installed equipment.

4.0 PIPELINES AND PRE-FABRICATED PIPEWORK

4.1 All pipe flanges shall be kept free from damage and temporary preservative or flange covers applied when
the pipeline fabrication was undertaken. They shall not be removed except for inspection, cleaning, testing
and installation to minimize the damage and deterioration that can occur.

4.2 Straight lengths of pipe must be correctly stacked. If there are no formally designed pipe racks then the
pipework may be laid on timber and stacked in a pyramid style with no stack exceeding 6.5 ft (2 m) for
pipe up to 12in (300 mm) diameter and no more than 9.75 ft (3 m) high for larger pipes. There shall be
retaining wedges at the outside of the stack firmly secured to the supporting timbers on which the pipe
rests. Loose wedges shall not be used.

4.3 Formal pipe racks shall be designed and constructed to accept a range of pipe sizes. The maximum distance
between upright supports shall not exceed 6.5 ft (2 m). Pipes shall not be stacked higher than the supports
at any time.

4.4 Fabricated pipework shall be offloaded onto timber. Due to the complex shapes of prefabricated pipe
spools they are normally not stacked. All flanges shall be protected with wooden or plastic end covers. All
butt weld preparations shall be sealed by plastic caps or wooden covers taped into place. Pipe spools shall
be laid down in defined areas and, where practical, all of the spools for an isometric drawing shall be stored
together.

4.5 When pipework or pipes are required for site installation and fabrication, the construction Contractor shall
confirm the identity of each spool, each size, grade and class of each straight length of pipe and any fittings
required for fabrication against the appropriate isometric diagram. Materials shall be delivered to the
construction area in isometric construction sequence to avoid mix up between similar items on different
drawings.
 GENERAL ENGINEERING SPECIFICATION GES C.02
PROTECTION OF MATERIALS AND EQUIPMENT Page 6 of 7
DURING CONSTRUCTION Rev 0 1999

4.6 Any pipe spool, fitting or straight length of pipe that cannot be positively identified against the isometric
drawing due to inadequate identification, shall be quarantined until the identification can be re-established.

4.7 During installation care shall be taken to avoid arc strikes on the material surface. On low alloy materials
arc strikes outside of the weld zone will lead to high stress raisers and therefore the welder shall carry a
strike plate to strike his arc. Tape shall be applied either side of the weld zone to prevent the occurrence of
accidental arc strikes. This is a typical problem in the field fabrication of manifolds, where the access for
welding is restricted. Arc strikes on pipelines, or equipment, especially in sour service, shall be avoided as
it may result in early failure.

4.8 All electrical connections to pipeline instrumentation are to be isolated during construction. Where practical
no instrumentation is to be connected to the pipeline during the fabrication stage, in order to avoid
accidental exposure to welding currents.

4.9 All valves, instruments and mechanical equipment items associated with a particular line shall either be left
out with distance pieces used for construction purposes, or temporary blanks fitted between these items and
the pipeline to prevent any debris from fabrication entering the equipment itself.

4.10 All temporary strainers are to be installed where specified in the installation procedures. Where practical,
these are to be fitted with a finer mesh than that to be used in service.

4.11 On certain types of valves, particularly those with weld ends and subject to stress relieving, the internals
may be removed during fabrication and testing. When this is permitted by the line specifications, then the
removed internals shall be formally packed, preserved as necessary, and identified with the valve serial
number as well as any other required identifiers.

4.12 Primed pipe spools shall be handled using flat non-metallic web slings to avoid damage.

5.0 PRESSURE TESTING

5.1 The following general guidelines shall be followed to protect equipment while performing in-situ pressure
testing of plant/production facility systems. Detailed test procedures shall be developed for each case, in
strict compliance with the methods and procedures provided in the established codes of practice such as
ANSI B 31.3, 31.4, 31.8, ASME applicable sections, with needed modifications as required, and approval
obtained from the authenticated bodies.

5.2 Any hydraulic testing that takes place must be with potable water, or specially treated low chlorine content
water, with a corrosion inhibitor included to prevent rusting from residues.

5.3 Relief valves on process lines will not be fitted during the full hydrostatic test, however there must be
precautions in place to prevent over pressurisation. As a minimum two (2) calibrated pressure test gauges
must be used during testing to ensure there can be no accidental over pressurisation if one should fail to
read correctly. Pressure relief valves are to be calibrated before installation.

5.4 All necessary safety precautions must be followed when testing. In addition special attention must be taken
to protect equipment that is in the immediate vicinity of points of discharge from pipework, especially
where purging and flushing operations take place.

5.5 Relief/Safety valves on hydraulic packages/systems will not be removed for testing except under the direct
instruction of the Inspector or Inspection Authority to avoid contamination of the hydraulic circuits.

5.6 After testing all lines shall be drained and internals dried by blowing dry air. The dryness can be confirmed
by a hygroscopic test on the outlet air. Rust inhibitors shall to be applied and surfaces preserved if the
lines/vessels are to remain out of service for extended periods. Alternatively, rust prevention can be
achieved by the application of other proprietary type mist inhibitors or vapour barriers.
 GENERAL ENGINEERING SPECIFICATION GES C.02
PROTECTION OF MATERIALS AND EQUIPMENT Page 7 of 7
DURING CONSTRUCTION Rev 0 1999

6.0 EQUIPMENT

6.1 All items of mechanical equipment shall be sited without removing any protective coverings unless it is
unavoidable. Any covers removed shall be replaced after equipment has been installed and this must be
done at the earliest possible opportunity.

6.2 All small diameter pipes, tubes and other delicate pieces of equipment shall be protected against
mechanical damage during handling and installation.

6.3 When the equipment, associated pipework, cabling and instrumentation has been installed, then it can be
made ready for commissioning. As part of the preparation any preservatives and temporary attachments,
locking devices, etc. shall be removed. Connecting pipework shall only be attached when there is positive
evidence that cleaning of the equipment and flange faces has been completed.

6.4 No equipment shall be started up until it is positively confirmed that all lubricants, and other operational
fluids, have been applied and all lines are clear. All temporary bracing shall be removed.

6.5 Rotating equipment may have become off balanced during transit and/or installation, therefore all
precautions shall be taken to ensure no further damage occurs by starting up equipment that has been
installed incorrectly. All start ups are to be made in incremental stages, so that equipment can be quickly
shut down in the event of a problem without creating additional problems or damage.

6.6 All installed equipment shall have all unpainted threads, and bare shafts such as those used for operation
and adjustment, protected by grease or preservatives so it is in a satisfactory status at the time of start up.

7.0 PROTECTIVE COATINGS

7.1 All protective coatings shall be protected by taking care during handling. All equipment shall be lifted by
its lifting lugs, where fitted, using any specified lifting device or spreader bars to avoid damage and to
ensure a safe lift. Webbing slings are preferred where they can be used within their safe working load. An
alternative is to use protective mats between the item being lifted and any slings.

7.2 Where the protective coating becomes damaged it must be assessed quickly to ensure that there is no
danger of corrosion taking place. If the coating is only damaged superficially, then it can be repaired as part
of final touch up work. Where the coating is damaged to a point that the metal surface is exposed, then a
full or temporary repair must be carried out as quickly as possible.

7.3 Damaged coatings shall be restored in accordance with the project specifications.

S:\NOC9077\ADMIN\SPECIFICATIONS\C-SERIES\C-02\GESC02RF
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.03

SAFETY PROCEDURES ON CONSTRUCTION SITES

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 2 of 19
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Other NOC Specifications 3

2.0 DEFINITIONS 4

2.1 Technical 4
2.2 Contractual 4

3.0 CONSTRUCTION PROJECT SAFETY MANAGEMENT 5

3.1 Historical Accident Data 5

3.2 Safety Management Aims and Responsibilities 5
3.3 Safety Management Structure 6
3.4 Construction Phase Safety Plan 6
3.5 Vendor/Contractor Responsibilities 6

4.0 CONSTRUCTION SITE SAFETY 8

4.1 Construction Site Organisation 8

4.2 Fire Prevention 9
4.3 Working at Height 10
4.4 Excavating 12
4.5 Formwork and Reinforced Concrete Work 12
4.6 Confined Spaces 13
4.7 Moving, Lifting and Handling Loads 13
4.8 Site Vehicles and Mobile Plant 14
4.9 Electrical 15
4.10 Safety Inspections 17
4.11 Pre-commissioning Phase 19
 GENERAL ENGINEERING SPECIFICATION GES C.03
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Rev 0 1999

1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for safety procedures on construction sites. Although
it is written essentially for new construction, the Owner may also choose to specify its use for maintenance,
repairs, extensions, renovation, demolition or other construction works.

1.1.2 This specification applies to the construction of refineries, onshore oil and gas installations and processing
facilities.

1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.4 In the event of any conflict between this specification and any other documentation issued by the Owner, or
with any of the applicable codes and standards, the Vendor/Contractor shall inform the Owner in writing
and receive written clarification before proceeding with the work.

1.1.5 This General Engineering Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

Where indicated in this specification, the following additional NOC Specifications shall apply:

GES A.01 Plant Layout and Spacing

GES A.04 Noise Level Criteria and Noise Control of Mechanical Equipment

GES C.05 Mechanical Equipment Installation Practices

GES C.06 Electrical Installation Practices

GES C.57 Chemical Cleaning of New Piping

GES C.59 Cleaning and Purging of Oil and Gas Pipelines

GES C.60 Plant Pre-Commissioning, Commissioning and Start-Up Guidelines

GES H.02 Safety Signs and their Applications

GES H.03 Portable Fire Extinguishers

GES H.09 Emergency Shower and Eyewash Facilities

GES H.10 First Aid and Medical Facilities

GES H.11 Protective Clothing and BA Sets

GES I.07 Inspection of Lifting Equipment

GES L.35 Electrical Equipment in Hazardous Areas

2.0 DEFINITIONS

2.1 Technical
 GENERAL ENGINEERING SPECIFICATION GES C.03
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Rev 0 1999

The technical terms used in this specification are defined as follows:

Safety

Avoid risks, danger and hazards.

Hazard

The potential to cause harm to personnel and damage to property.

Consequence

The likely severity of personnel injury, business interruption and property damage from a particular hazard.

Frequency

The likelihood for the occurrence of a particular hazard per unit time.

Risk

A multiple of consequence and frequency, a high risk thus incorporating a high likely severity and a high
likelihood of occurrence.

So far as reasonably practicable

Ensuring that the degree of risk accepted is properly balanced against the cost, physical difficulty, and time
required to avoid the risk.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.
 GENERAL ENGINEERING SPECIFICATION GES C.03
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Rev 0 1999
Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 CONSTRUCTION PROJECT SAFETY MANAGEMENT

3.1 Historical Accident Data

The Safety Management of any construction project shall take into account the fact that statistical studies of
construction site accidents typically show that:

(a) The principal causes of construction site fatalities are:

- falls from a height (55%);

- trapped by something collapsing or overturning (20%);
- struck by a moving vehicle (10%);
- electricity (5%);
- struck by falling/flying object during machine lifting of materials (5%);
- contact with moving machinery (3%);
- exposure to hot or harmful substance (1%);
- others (1%).

(b) The principal injuries and subsequent illnesses suffered during construction are:

- musculoskeletal injury (75%);

- respiratory disease (15%);
- skin disease (6%);
- permanent hearing impairment (1%);
- other (3%).

3.2 Safety Management Aims and Responsibilities

3.2.1 For each phase of the construction project the aim shall be to:

- identify the significant safety hazards and their frequencies that are likely to be associated with
that phase of the project;
- consider the risk from those hazards;
- minimise those risks so far as reasonably practicable and produce risk assessments and method
statements.

3.2.2 For hazards which cannot be totally eliminated, priority shall be given:

- firstly to those controls which protect all workers (e.g. plan the early installation of stairways for a
new structure and provide fixed handrails on walkways);
- secondly to the protection of individual workers (e.g. issue harnesses).

3.2.3 All parties have a duty to co-operate and pass on relevant information.

3.2.4 Safety shall be given due consideration in all aspects of construction and shall not be an after thought.

3.3 Safety Management Structure

3.3.1 Safety performance on construction sites is affected by the considerations given during all phases of the
project, from conceptual design to the completion of commissioning. Furthermore, decisions made during
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 6 of 19
Rev 0 1999
design and engineering will significantly affect safety during the construction, post-construction operation
and maintenance of the installation which has been constructed. All project phases shall be the subject of
appropriate Safety Management, however, this specification is limited to the construction phase aspects.

3.3.2 The Safety Management of a construction project shall be based upon the preparation and implementation
of the following key safety document:

- the Construction Phase Safety Plan, prepared prior to starting the construction work.

The requirements for this document are given below.

3.4 Construction Phase Safety Plan

3.4.1 The Construction Phase Safety Plan shall be prepared by the Vendor/Contractor and shall contain all
relevant safety information for the construction and commissioning phases together with the necessary
recommendations to bring down risks to as low as reasonably practicable.

3.4.2 As a minimum, the Construction Phase Safety Plan shall contain the following information:

(a) Manpower

estimated maximum site manpower levels;

planned number of sub-contractors on site.

(b) Procedures

general construction and pre-commissioning safety and welfare procedures;

work permit system;
significant hazards of special work sequences plus the required precautions;
training requirements;
emergency procedures;
risk assessments;
method statements.

3.5 Vendor/Contractor Responsibilities

3.5.1 The Vendor/Contractor shall have the overall responsibility for co-ordinating the safety aspects of the
construction and pre-commissioning phases.

3.5.2 The Vendor/Contractor shall ensure:

- the Construction Phase Safety Plan is prepared such that it contains all necessary information for
the effective management of the safety and welfare of all persons on the construction site
(including adequate arrangements for monitoring compliance with this specification).
 GENERAL ENGINEERING SPECIFICATION GES C.03
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Rev 0 1999

3.5.3 Throughout construction and pre-commissioning, the Vendor/Contractor shall ensure that:

- risk assessments are prepared for each activity;

- method statements are prepared giving details of how it is intended to perform the work;
- organisation, monitoring and reviewing of all construction and pre-commissioning work;
- only authorised persons are allowed access to the site;
- the Construction Phase Safety Plan is implemented on site for the duration of the construction and
commissioning phases;
- any requirement to change the Construction Phase Safety Plan after construction begins is discussed
and agreed with the Owner before such changes are implemented;
- all relevant safety information is communicated to (and where necessary discussed with) the Owner;
- all equipment used on site is in safe working order and properly used;
-- all persons on site are adequately informed of the risks on site;
- all persons on site are adequately trained or experienced to deal with the expected risks;
- all persons on site are given adequate opportunity to discuss and offer advice on all matters affecting
their safety on site.

3.5.4 Other NOC Specifications shall be used as appropriate in planning and performing the construction work,
including the following specifications:

GES C.05 Mechanical Equipment Installation Practices

GES C.06 Electrical Installation Practices

GES C.57 Chemical Cleaning of New Piping

GES C.59 Cleaning and Purging of Oil and Gas Pipelines

GES H.02 Safety Signs and their Applications

GES H.03 Portable Fire Extinguishers

GES H.09 Emergency Shower and Eyewash Facilities

GES H.10 First Aid and Medical Facilities

GES H.11 Protective Clothing and BA Sets

GES I.07 Inspection of Lifting Equipment

3.5.5 Before the work begins, the Vendor/Contractor shall give particular attention to the following:

- take a leading role in preparing co-ordinated emergency procedures for gas leak, fire and explosion;
- ensure that emergency procedures have been communicated to all persons on site.

3.5.6 The Vendor/Contractor shall provide the Construction Phase Safety Plan in writing and it shall be based on the
construction site safety requirements outlined in Sections 4.1. to 4.11 of this specification.

3.5.7 The Vendor/Contractor shall promptly advise the Owner of all accidents including any death, injury,
dangerous incident or traffic accident which occurs on site or in connection with the project.

4.0 CONSTRUCTION SITE SAFETY

4.1 Construction Site Organisation

 GENERAL ENGINEERING SPECIFICATION GES C.03
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Rev 0 1999
4.1.1 The Vendor/Contractor shall appoint a safety officer who shall liaise with the Owner as necessary and
ensure that all aspects of construction site safety as outlined in this specification are implemented,
monitored, controlled and audited.

4.1.2 All persons working on a construction project shall be appropriately supervised.

4.1.3 All persons engaged to work on a construction project shall either:

- provide evidence that they are adequately skilled in the work they have to do (e.g. by providing
appropriate certificates or evidence of previous experience), or
- be given adequate training to enable them to do their work safely.

4.1.4 Safety training shall be provided as necessary on all known hazards, including:

- the safe use of materials and equipment;

- emergency procedures;
- the use of portable fire extinguishers.

4.1.5 Effective emergency procedures, as noted in Section 3.4.2, shall be planned before work begins, taking into
account such factors as:

- the type of work to be done;

- the characteristics and size of the construction site;
- the number and location of workplaces on the site;
- the plant and equipment being used;
- the hazardous materials present;
- the number of people likely to be present.

4.1.6 Throughout the work, precautions shall be taken to ensure that:

- the likelihood of emergencies arising is as low as possible;

- everyone on site is informed of the emergency signals;
- everyone can be alerted in an emergency;
- everyone knows what to do if the signal is given;
- emergency routes are available, clear, signed and adequately lit;
- there are arrangements for calling the emergency services.

4.1.7 Throughout the work, the Vendor/Contractor shall ensure the provision of:

- emergency shower and eyewash facilities in accordance with GES H.09;

- first aid and medical facilities in accordance with GES H.10;
- appropriate personal protection equipment (PPE) to all persons on site in accordance with GES
H.11, with a requirement to use it in the intended manner;
- adequate welfare facilities, including toilets, washing facilities & drinking water.

4.1.8 Throughout the work, the Vendor/Contractor shall ensure that:

a) All systems and equipment are properly selected and installed in the following manner:

- safe work procedures are followed with the use of equipment, taking into account
manufacturers' instructions;
- all visitors to report to the site office;
- defective materials and equipment shall immediately be reported;
- appropriate investigation, reporting and follow-up of all dangerous situations and
accidents is carried out.

b) All hazardous materials are:

 GENERAL ENGINEERING SPECIFICATION GES C.03
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Rev 0 1999

- identified and supplied with hazardous material data sheets which list significant safety,
fire and environmental hazards;
- supplied with advice how best to avoid these hazards;
- supplied with instructions on the required action in event of an accident;
- used, stored and transported safely, with consistent use of personal protection equipment,
forced ventilation and other precautions as appropriate.

c) Appropriate attention is paid to general housekeeping as follows:

- walkways and stairs are kept free of tripping hazards;

- nails in loose timbers are removed or hammered flat;
- flammable waste is routinely collected;
- unused hazardous materials are properly disposed of;
- a formally-defined structure of safety meetings is implemented, such that all persons
working on the site attend regular meetings held in a language which they adequately
understand and safety concerns identified by meetings are appropriately followed up.

4.2 Fire Prevention

4.2.1 Where flammable construction materials or consumables are present, appropriate precautions shall be taken
against the risk of fire, including those listed below:

4.2.2 Fire prevention precautions shall include:

- using less easily ignited and fewer flammable materials where possible;
- keeping the quantity of flammables at the workplace to a minimum;
- storing flammables safely and separate from oxidising materials;
- locating work in an un-obstructive area where it can proceed unhindered with no obstructions or
possibility of endangered escape routes;
- keeping and transferring flammable liquids in suitable closed containers;
- controlling fixed and mobile ignition sources;
- switching off all plant and equipment which could cause fire when not in use;
- purging spaces which previously contained flammables with nitrogen before starting hot work;
- controlling the use of compressed gases, in particular ensuring:

- strict colour coding and segregation of oxygen and flammable gas bottles;
- prevention of oil or grease coming into contact with oxygen bottles;
- consistent use of thread protectors, and chaining bottles stored vertically;
- regularly removing rubbish from site;
- having appropriate fire extinguishers to hand during all hot work.

4.2.3 The following precautions shall be put in place to control the fire:

- temporary alarm systems, such as a siren warning system;

- primary and secondary escape routes, separated as far as practicable;
- fire extinguishers in accordance with GES H.03 at identified fire points around the site (in addition
to those used for hot work standby);
- rapid communication links with emergency services/fire stations.

4.3 Working at Height

4.3.1 When deciding whether a particular piece of work at height should be done using a scaffold, tower
scaffold, mobile elevated working platform, ladder, or personal suspension equipment the following factors
shall be considered:

- how long the work will last;

 GENERAL ENGINEERING SPECIFICATION GES C.03
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Rev 0 1999
- any hazards associated with erecting, maintaining, and dismantling a fixed platform;
- how many people will need to use the equipment;
- whether any part of the structure can be provided early in the work so that there is a permanent
working platform;
- weather conditions and wind forces which may arise during the work;
- only when it is impractical to provide a work platform with guard rails shall other means of access
be used;
- only when no other method is practicable should a way of arresting falls (e.g. harness and lines or
nets) be relied upon.

4.3.2 All general access scaffolds shall be:

- designed, erected, altered and dismantled by competent people, competently supervised;

- subject to a material check before being erected;
- based on firm, level foundations, with baseplates positioned boards to prevent them from sinking
into soft ground if required;
- braced and tied into a permanent structure or otherwise stabilised;
- capable of supporting loads likely to be placed upon them;
- fitted with working platforms.

4.3.3 Working platforms shall be:

- provided with safe access;

- fully boarded, with the boards not overhanging by more than four times their thickness;
- at least 2 ft (600 mm) wide;
- free of openings, traps and tripping and slipping hazards;
- constructed to prevent materials falling;
- fitted with guard rails and toe boards whenever persons or materials could fall 6.5 ft (2 m) or more
from the platform, with the guard rails:

- being fixed to a structure capable of supporting them;

- including main guard rails at a height of at least 3 ft (910 mm) and intermediate guard
rails (or mesh) such that unprotected gaps are not more than 1.5 ft (470 mm) high;
- the toe boards being at least 6 in (150 mm) high.

4.3.4 Tower scaffolds (free-standing, usually wheeled) shall:

- stand vertically, with the legs resting properly on firm, level ground;
- have their wheels and outriggers locked;
- have guard rails and toe boards as for general access scaffolds;
- be tied rigidly to the structure it is serving if:

- sheeted and/or likely to be exposed to significant wind forces;

- used for grit blasting or water jetting;
- heavy materials are to be lifted up the outside of the tower;
- the tower base is too small to ensure stability for the platform height.

Tower scaffolds shall NOT be:

- subjected to horizontal loads which could tilt the tower;

- used to transport people or materials.

4.3.5 Mobile, self-elevating access equipment shall be subject to the following checks:

Before work starts :

- the equipment is appropriately certified;
- the operator is appropriately qualified;
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 11 of 19
Rev 0 1999
- tyres are properly inflated;
- the ground is firm and level;
- any associated outriggers are extended and chocked as necessary;
- weather conditions are suitable.

At the end of each day:

- the platform is cleared of tools and equipment;
- all power has been switched off.

Mobile, self-elevating access equipment shall NOT be moved with the working platform in the raised
position unless designed for such operation.

4.3.6 Suspended access equipment shall be subject to the following checks:

Before work starts :

- the equipment is appropriately certified;
- counterweights and holding down systems are in order;
- the equipment is capable of fitting closely to the structure;
- buffers or rollers (where fitted) will run as intended;
- the support structure can take the weight of the suspended equipment;
- a secondary safety rope fitted with a fall arrest device and attached to a separate suspension point
is fitted;
- the work plan is based upon an adequately uniform platform loading;
- the operator is appropriately qualified;
- there is safe access to the equipment;
- weather conditions are suitable.

At the end of each day:

- the equipment is cleared of tools and materials;
- all power has been switched off.

4.3.7 Ladders shall be subject to the following checks before work starts:

- the ladder is in good condition;

- it is properly angled (at approximately 3.25 ft (1 m) out for every 13 ft (4 m) up);
- have both feet on firm footing;
- have the top resting against a solid surface with at least 3.25 ft (1 m) extending above any landing
place (unless other adequate handhold is available);
- be fixed to prevent slipping if more than 9.75 ft (3 m) long;
- be used such that the work can be reached without stretching;
- NOT be used to transfer unduly heavy or bulky loads.

4.4 Excavating

4.4.1 Before any trenches, pits, tunnels or other excavations are dug, required safety precautions, including any
temporary supports, shall be determined to protect against the collapse of the sides by:

- battering to a safe angle or supporting with sheeting or proprietary support systems;

- installing supports without delay as the excavation progresses;
- storing excavated spoil and other materials, locating heavy equipment, and parking vehicles at a
safe distance;
- requiring those working in excavations to wear hard hats;
- surveying the foundations of adjacent structures before excavation begins;
- determining in advance the presence of underground services;
- keeping new excavations away from existing underground services if possible;
- hand digging near buried cables and pipes;
- prohibiting the use of hand-held power tools within 20 in (0.5 m) of the expected position of
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 12 of 19
Rev 0 1999
buried piping;
- treating all pipes and cables as 'live' unless it is stated otherwise;
- prohibiting the cutting or breaking of any existing services until it is clearly safe to do so;
- prohibiting the use of a machine to excavate within 20 in (0.5 m) of any buried piping;
- supporting buried piping once they are exposed;
- backfilling around pipes and cables with fine material;
- stopping work if unidentified underground services are discovered;
- updating underground service drawings once new services have been laid;
- piping away the fumes from any engines to be operated in the excavation and/or providing forced
ventilation.

4.4.2 Excavation equipment and materials needed (such as trench sheets, props, baulks etc.) shall be available on
site before work starts.

4.4.3 Preference shall be given to the use of systems which allow trench supports to be put in place without
requiring people to enter the excavation.

4.4.4 Emergency procedures shall be in place before the work begins, including specific actions required in the
event of damage or suspected damage to any live underground services.

4.5 Formwork and Reinforced Concrete Work

4.5.1 Appropriate precautions shall be taken against the following principal risks:

- people falling during steel fixing and erection of formwork;

- collapse of the formwork or falsework;
- materials falling while striking the formwork;
- manual handling of shutters, reinforcing bars, etc;
- silica dust from scabbling operations;
- arm and back strain;
- cement burns from wet concrete;
- formwork, falsework and temporary supports shall be properly tied, footed, braced and supported
before loading and before pouring;
- loads shall be spread as evenly as possible on temporary structures;
- back propping shall be applied as appropriate;
- there shall be a safe striking procedure in place.
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 13 of 19
Rev 0 1999
4.6 Confined Spaces

4.6.1 Safety precautions for confined spaces shall particularly address the specific risks of:

Toxic and/or flammable gases and fumes:

- gas build-up in pits or spaces in which hydrocarbons were previously present;

- gas migration though piping and tunnel systems.

Oxygen deficiency;

- chemical reactions which reduce oxygen content (e.g. rusting of steel or oxidation of soils);
- combustion reactions which decrease oxygen and increase carbon dioxide content.

4.6.2 Before anyone is permitted to enter a confined space such as vessels and tanks the following precautions
shall be taken:

- all such activities shall be controlled by means of the work permit system;
- the space shall be well ventilated and then checked using appropriate instruments for oxygen
deficiency, flammability and toxicity;
- if natural ventilation is considered to be inadequate then appropriate forced ventilation shall be
provided;
- deposits in the confined space which could possibly produce additional vapours when disturbed
shall be removed by trained personnel using breathing apparatus.

4.6.3 If the air inside the confined space cannot be kept safe for breathing then:

- under no circumstances shall an attempt be made to 'sweeten' the air with oxygen as this can
produce fire and explosion risks;
- all persons entering the space shall use breathing apparatus;
- consideration shall be given to the possible need for lifelines, running to an open space.

4.6.4 For the entire time that someone is in the enclosed space without the continuous use of breathing apparatus,
air quality shall be frequently checked.

4.6.5 Regardless of whether those inside the confined space are wearing breathing apparatus or not, somebody
who has been appropriately trained shall stand by outside the entrance to the space to keep watch and raise
the alarm in any emergency.

4.7 Moving, Lifting and Handling Loads

4.7.1 Material moving, lifting and handling shall be planned before the work starts.

4.7.2 All moving, lifting and handling equipment shall be:

- properly certified and/or colour coded;

- visually inspected before use;
- used in the proper manner;
- made safe at the end of the work, the shift, or the day, as appropriate.

4.7.3 All non-standard heavy loads shall have their weights clearly marked on them.
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 14 of 19
Rev 0 1999
4.7.4 The risk of accidents with manual handling shall be minimised by:

- avoiding unnecessary handling;

- using mechanical aids optimally;
- training workers in safe lifting techniques;
- prohibiting the lifting by a single person of any load weighing more than 44 lb (20 kg).

4.7.5 The risk of accidents with small lifting equipment shall be minimised by:

- fixing pulleys and gin wheels to a secure anchorage;

- using only hooks which are specially designed to prevent displacement of the load (preferably fitted
with a safety catch);
- ensuring that there is a safe working platform from which the hook can be loaded and unloaded.

4.7.6 The risk of accidents with hoists shall be minimised by:

- clearly marking the hoist with its safe working load;

- setting the controls up such that the hoist can be operated from one position only, and
the operator can safely see all landing levels from the operating position;
- enclosing the hoistway at places where people might be struck or fall down the hoistway;
- providing gates at all landings and at ground level;
- providing the hoist platform with sides high enough to retain loose materials or putting loose
materials into appropriate containers;
- ensuring that loads are evenly distributed on the hoist platform;
- prohibiting the transfer of people by hoist.

4.7.7 The risk of accidents with mobile cranes shall be minimised by taking the following measures:

- ensuring before initiating the work that the crane has an Automatic Safe Load Indicator in good
working order;
- plan the lift in such a manner that the crane selected is adequate for the maximum moment to be
applied (i.e. the most demanding combination of load and horizontal lifting distance);
- the crane will be used well away from excavations and overhead power lines;
- the crane will be used on level ground which can take the full weight of the crane and its maximum
load;
- the crane shall NOT be used over voids such as drains or basements which could collapse suddenly;
- while the crane is in use the driver will have clear view of the work or there shall be a system of
visual signals in place from a banksman or signaller who will have a clear view of the work;
- lift shall be co-ordinated in a manner that outriggers are employed as necessary;
- the crane shall be positioned to give adequate clearance around the counterweight;
- at all times the load shall be properly slung, with the centre of gravity beneath the hook;
- slings shall be protected by packing around the load;
- if the load is suspected, to swing around, particularly in windy conditions then it shall be fitted with
tail line to control the movement.

4.8 Site Vehicles and Mobile Plant

4.8.1 There shall at all times be safe access onto and around the plant.

4.8.2 As far as practicable, there shall be separate access routes for pedestrians and vehicles.

4.8.3 Consideration shall be given to the possibility of imposing a one-way system.

4.8.4 There shall be dedicated vehicle loading/unloading, parking, and manoeuvring places.

4.8.5 All vehicles permitted access to the site shall have visual and audible reversing alarms.
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 15 of 19
Rev 0 1999
4.8.6 Particular attention shall be given to the possible need to protect temporary structures and emergency
equipment from being struck by vehicles.

4.8.7 All vehicles shall be used in the intended manner. In particular, the transportation of people by vehicles not
designed for that purpose shall be strictly prohibited.

4.9 Electrical

4.9.1 Throughout the construction phase, the safety implications of the following shall be kept under appropriate
review:

- earthing requirements;
- installation, commissioning and use of temporary site distribution systems;
- the way in which the system will be modified or extended as the work progresses;
- provision of lockable switches and isolation systems;
- correct rating of fuses and switchgear;
- the identification of parts which are live;
- the location of equipment and systems which need to be accessible at all times in case of emergency .

4.9.2 Where risks of using electrical systems are particularly high (e.g. on waterlogged sites or in confined spaces),
consideration shall be given to using pneumatic systems.

4.9.3 All electrical equipment which is to be used where there is a risk of flammable atmospheres shall comply with
GES L.35.

4.9.4 Unless otherwise agreed in writing by the Owner, the following voltages shall not be exceeded for the
applications listed:

- portable hand lamps for use in confined or damp situations: 25 V single phase;
- other portable hand lamps: 50 V;
- site lighting other than fixed floodlighting: 110 V reduced low voltage single phase;
- portable and hand-held tools and transportable equipment not exceeding 5 hp (3.7 kW): 110 V
reduced low voltage, single or 3 phase;
- installations in site offices and fixed floodlighting: 230 V single phase;
- fixed or moveable heavy duty plant: 400 V 3 phase.

4.9.5 Generators shall meet the following requirements:

- generators with outputs in excess of 10 kVA shall be earthed by bonding the neutral to the frame and
connecting the frame to earth;
- the impedance of the bonding to be low enough to ensure correct operation of protective devices
(fuses, circuit breakers etc.);
- portable generators with outputs not exceeding 10 kVA need not be earthed provided that they are
used only for short time work (e.g. less than one day), and with Class II (double insulated or all-
insulated) tools or equipment;
- generators with outputs not exceeding 5 kVA (single phase generators used for 110 V supplies) need
not be earthed provided that all equipment supplied is double insulated or only one item of 'earthed'
equipment is supplied, and the equipment is bonded with the frame of the generator;
- in all other circumstances, a suitable earth shall be provided.

4.9.6 Earthing of the site supply shall meet the following requirements:

- if protective multiple earthing (PME) is used (with neutral and earth combined) all metalwork,
including structural metalwork, shall be bonded together;
- if the work involves extending an existing site whose electrical system is supplied with a PME system
then temporary site distribution systems shall be kept separate of the PME system;
- fixed cable armouring and metal conduit may be used as the earthing conductor, flexible metallic
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 16 of 19
Rev 0 1999
conduit shall NOT be used as the only earthing conductor;
- particular attention shall be paid to providing good electrical connection between various components
(e.g. between conduit, cable glands and equipment);
- earthing shall be tested after an item of equipment has been installed, paying particular attention to
conductor continuity, polarity, and insulation resistance.

4.9.7 Trip devices (e.g. residual current devices (RCDs) with a rated tripping current of not more than 30 mA, and a
non-adjustable rated operating time of 200 ms) shall be:

- installed in mains systems at the earliest opportunity;

- fitted to individual circuits (to avoid tripping of the total site supply);
- mounted in rustproof, weatherproof enclosures;
- kept free of moisture and dirt/dust;
- protected against vibration and mechanical damage;
- checked daily by operating the test button;
- visually inspected weekly together with the equipment supplied;
- tested every three months by an electrician (at a time when loss of power will not endanger other
work activities).

4.9.8 Users of electrical equipment shall be made aware that the degree of protection given by RCDs is limited by
various factors, including the following:

- they protect only against earth faults and will not operate when there is no connection to earth;
- they are not reliable on portable apparatus which may receive mechanical shock or on equipment
which vibrates;
- failure of an RCD is not apparent to the worker;
- an RCD will not make a system safe if it has been poorly designed or installed.

4.9.9 Distribution cables shall be:

- of a type which has metal sheath and/or armour appropriately protected against corrosion;
- positioned where they are least likely to be damaged;
- protected against mechanical damage;
- located in ducts at least 20 in (0.5 m) below the surface if they are run beneath roads.

4.9.10 Moveable electrical equipment supply lines shall be:

- armoured cable for equipment which is moved only occasionally (e.g. hoists);
- flexible cable with protective braid and abrasion-resistant sheath for equipment which is moved
frequently (e.g. cement mixers).

4.9.11 Temporary site distribution systems, new permanent installations and extensions or alterations to existing
systems shall be tested on completion and be approved by the Owner if found to be in order.

4.9.12 Equipment which is connected to the site supply shall meet the following requirements:

- all electrical equipment shall be of robust, industrial type;

- domestic type electrical components shall be prohibited on site;
- equipment which is not double insulated or all insulated shall be earthed, using a three core cable;
- all extension leads shall be of three core construction having a separate earth conductor;
- all equipment can be isolated before the separation of the plug and socket for equipment having a
current rating of 16 amps or more;
- electric lights shall be protected against mechanical damage.

4.9.13 Portable electrical equipment shall meet the following requirements:

- preference shall be given to cordless tools and tools which operate from a 110 V supply system
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 17 of 19
Rev 0 1999
which is centre-tapped to earth so that the maximum voltage to earth does not exceed 55 V;
- plugs and sockets on reduced low voltage systems shall NOT be interchangeable with those of
higher voltage systems;
- plugs, sockets and couplers shall be colour coded to indicate voltage;
- unless otherwise stated in writing by the Owner, the following colours shall apply:

violet = 25 V
white = 50 V
yellow = 110 V
blue = 230 V
red = 400 V

- no bare wires shall be visible;

- the cable covering shall not be damaged;
- the cable shall have no non-standard joints;
- the cable shall be gripped where it enters the plug or equipment;
- the plug and socket shall be in good condition;
- no screws shall be missing;
- there shall be no visible signs of the plug, cable or equipment having overheated.

4.10 Safety Inspections

4.10.1 Safety inspections shall be carried out by the Vendor/Contractor's safety personnel as follows:

- before work on individual activities is started, check that working conditions are safe before work
begins and ensure that the proposed work will not put others at risk;
- regularly ensure that the requirements of this specification are being continuously met for the site
in general.

4.10.2 Appropriate written inspection records shall be kept by the Vendor/Contractor's safety personnel.

4.10.3 All inspection reports shall contain the following information:

- name and department of person on whose behalf the inspection was carried out;
- identification and brief description of the workplace or item inspected;
- details of any action required to achieve required safety level;
- date and time of inspection;
- name and position of person making the report.

4.10.4 Separate copies of all inspection reports shall be promptly issued to:

- the Owner;
- the person in control of the workplace;
- the person most likely to take any corrective action required;
- retained by the Vendor/Contractor's safety groups until three months after the end of the
construction and commissioning phase.

4.10.5 Where it is possible for a person to fall 6.5 ft (2 m) or more from a working platform, the platform and
associated parts shall be inspected as follows:

- before first use;

- after substantial alteration;
- after any event likely to have affected its stability (e.g. stormy weather);
- at regular intervals not exceeding seven days.

These inspections shall ensure that:

 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 18 of 19
Rev 0 1999
- the platforms will support the weight of workers, materials and equipment which will be carried
by them;
- they are stable and will not overturn;
- they have been fitted with appropriate guard rails and toe boards.

4.10.5 Excavations which need to be supported or battered back to prevent danger shall be inspected:

- before work at the start of every shift;

- after any event likely to have affected its stability;
- after any accidental fall of rock, earth or other material.

4.10.7 Lifting equipment assembled on site shall be inspected, tested and certified by the Owner:

- after erection;
- after significant alteration and/or repair;
- at six month intervals;
- in addition, weekly visual checks shall be made and the results recorded.

4.10.8 Electrical equipment shall be inspected and tested with the following frequency:

Equipment/application Voltage User Formal visual Combined

check inspection inspection & test

Battery-operated power Less than No No No

tools and torches 25 volts

25 V Portable hand lamps 25 volts Secondary

(confined or damp winding from
situations) transformer No No No

50 V Portable hand lamps Secondary winding No No Yearly

centre tapped to
earth (25 volt)

110 V Portable and hand- Secondary winding Weekly Monthly Before first use
held tools, extension centre tapped to on site and then
leads, site lighting earth (55 volt) three monthly
moveable wiring systems
and associated switchgear

Equipment/application Voltage User Formal visual Combined

check inspection inspection & test

230 V Portable and hand 230 volt main Daily/ Weekly Before first use on
held tools, extension leads supply through every site and then
and portable floodlighting 30 mA RCD shift monthly

230 V Equipment such as 230 V supply Weekly Monthly Before first use on
lifts, hoists, and fixed fuses or MCBs site and then three
floodlighting monthly

RCD's Fixed ** Daily/ Weekly *Before first use on

every site and then three
shift monthly

Equipment in site offices 230 volt Monthly 6 Monthly Before first use on site and
then yearly
 GENERAL ENGINEERING SPECIFICATION GES C.03
SAFETY PROCEDURES ON CONSTRUCTION SITES Page 19 of 19
Rev 0 1999
NOTES:

* RCDs need a different range of tests to other portable equipment, and equipment designed to carry out
appropriate tests on RCDs will need to be used.
** Portable RCDs shall be tested monthly.

4.11 Pre-commissioning Phase

4.11.1 The Vendor/Contractor shall prepare jointly with the Owner, an agreed plant pre-commissioning
programme in good time. The participants shall ensure that:

- the programme is brought to the attention of all parties involved;

- plant commissioning procedures are adequate.

Regular weekly commissioning meetings shall be attended by all parties involved to:

- record past progress;

- arrange for the following week's work;
- manage deviations;
- work reported as complete is indeed complete;
- key information notes are issued immediately after each commissioning meeting;
- agreed procedures are being followed;
- there is adequate supervision;
- commissioned systems can clearly be distinguished from those not yet commissioned;
- commissioned systems not in use are appropriately locked off;
- live systems (e.g. live electrical systems or pressurised process equipment) are clearly identified.

S:\NOC9077\ADMIN\SPECIFICATIONS\C-SERIES\C-03\GESC03RF
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.05

MECHANICAL EQUIPMENT INSTALLATION PRACTICES

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES C.05
MECHANICAL EQUIPMENT INSTALLATION PRACTICES Page 2 of 26
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Design Conditions 6

4.0 PREPARATION FOR INSTALLATION WORK 6

4.1 Documentation 6
4.2 Specifications and Manuals 7

5.0 MATERIAL CONTROL 7

5.1 Material Supply 7

5.2 Site Storage and Material Receipt 7

6.0 SAFETY 8

6.1 Policy and Procedures 8

7.0 FOUNDATION INSPECTION 8

8.0 INSTALLATION OF MAJOR ITEMS 9

9.0 FIXING AND GROUTING 10

9.1 Rods and Anchor Bolts 10

9.2 Grout Mix Design 10
9.3 Mixing, Placing, Curing and Testing 10
9.4 Finishing of Grout 11

10.0 STEELWORK ERECTION 11

10.1 General 11
10.2 Marking 11
10.3 Handling 11
10.4 Erection Stresses 12
10.5 Installation of Grating 12
10.6 Installation of Floor Plates 12
10.7 Tolerances 12

SEC TITLE PAGE

 GENERAL ENGINEERING SPECIFICATION GES C.05
MECHANICAL EQUIPMENT INSTALLATION PRACTICES Page 3 of 26
Rev 0 1999
11.0 INSTALLATION OF ROTATING EQUIPMENT 12

12.0 CONNECTIONS AND BOLTED ASSEMBLIES 14

12.1 Field Connections 14

12.2 Bolted Assemblies 14

13.0 WELDING 15

13.1 Introduction 15
13.2 Welding Procedure Qualification 15
13.3 Welding Codes 15
13.4 Preheating 15
13.5 Residual Stresses 15
13.6 Stress Relieving 15

14.0 INSULATION 16

15.0 PAINTING 16

16.0 INSPECTION AND TESTING 16

16.1 General 16
16.2 Operational Preliminary Checks 17
16.3 Piping Preliminary Checks 17
16.4 Vessels Preliminary Checks 19
16.5 Rotating Equipment Preliminary Checks 22
16.6 Electrical Preliminary Checks 24
16.7 Instrumentation Preliminary Checks 25
16.8 General Preliminary Checks 25

17.0 AS BUILT DRAWINGS AND REPORTING 26

18.0 GROUNDING 26
 GENERAL ENGINEERING SPECIFICATION GES C.05
MECHANICAL EQUIPMENT INSTALLATION PRACTICES Page 4 of 26
Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification details the minimum acceptable standards applicable to the installation practices for
mechanical equipment. It covers the preparation of equipment for site conditions as well as safety checks and
gives guidance on materials, preparation, inspection, testing, installation and pre-commissioning.

1.1.2 For specific items or packages the Vendor/Contractor shall read this document in conjunction with the
applicable equipment specification, relevant Vendor/Contractor information, detailed design documents and
data sheets.

1.1.3 Compliance by the Vendor/Contractor does not relieve him of his responsibility to install the equipment in a
correct manner for its intended purpose. Any exception must be authorised in writing by the Owner.

1.1.4 This General Engineering Specification will form part of the Purchase Order/Contract for construction and
installation.

1.1.5 The Vendor/Contractor shall adhere to any restrictions placed on the use of tools and welding equipment
during construction and must comply with all safety regulations and precautions specified by the Owner.

1.2 Other NOC Specifications

Where indicated in this specification, the following NOC Specifications shall apply and any exceptions shall
be approved in advance by the Owner.

GES A.04 Noise Level Criteria and Noise Control of Mechanical Equipment

GES C.01 Protection of Materials and Equipment during Storage

GES C.02 Protection of Materials and Equipment during Construction

GES C.03 Safety Procedures on Construction Sites

GES I.05 Acceptance Criteria for Non-Destructive Examination

GES N.01 Thermal Insulation for Hot Service

GES N.02 Thermal Insulation for Cold Service

GES N.03 Acoustic Insulation for Piping and Equipment

GES P.01 Piping Material Specification

GES P.02 Plant Piping Systems

GES P.09 Steel Piping Fabrication (Shop or Field)

GES P.10 Erection and Testing of Steel Piping

GES Q.01 Earthworks (inc. Site Preparation, Pits and Trenches)

GES Q.03 Foundations (inc. Piling)

GES Q.04 Concrete Structures

GES W.01 Welding Procedure and Welder Qualifications

 GENERAL ENGINEERING SPECIFICATION GES C.05
MECHANICAL EQUIPMENT INSTALLATION PRACTICES Page 5 of 26
Rev 0 1999

GES X.01 Surface Preparation and Painting Application

GES X.02 Colour Coding of Equipment & Piping

GES X.03 External Protective Coatings

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Construction

This means all erection, installation, verification and testing. This shall be in accordance with the Owner's
requirements as shown in the approved construction drawings, project specifications, P&IDs etc.

Pre-Commissioning

The pre-commissioning phase shall include the three main types of field activities:

a) Systematic conformity checks, carried out on each item of equipment or component, such as pumps,
compressors, piping, valving, instrumentation etc., to verify visually the condition of the equipment,
the quality of the installation, the compliance with Project drawings and specifications,
manufacturer's instructions, safety rules, codes, standards and good practice.

b) Selected equipment static/de-energised tests, to ensure the quality of a number of critical components.
This "cold" testing concerns all disciplines, e.g. calibration of instruments, machinery alignments,
setting of safety valves, pressure testing of piping, cables continuities, etc.

c) Pipes and vessels, air, oil or water flushing, cleaning and reinstatement.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority
 GENERAL ENGINEERING SPECIFICATION GES C.05
MECHANICAL EQUIPMENT INSTALLATION PRACTICES Page 6 of 26
Rev 0 1999
The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and facilities
have been designed, constructed, inspected and tested in accordance with the requirements of this specification
and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority, who
verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance
with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The equipment inclusive of piping, machinery etc. shall fully comply with industry accepted codes of practice,
ASME/ANSI/ASTM/BS etc. as required by the relevant engineering specifications.

3.2 Design Conditions

Design pressures and temperatures for each mechanical package shall be specified by the Owner and these
must be met or exceeded by the equipment Vendor/Contractor's design. It is the responsibility of the
Vendor/Contractor to ensure that the correctly rated items as shown in the approval construction drawings,
project specifications, P&IDs etc. are installed.

4.0 PREPARATION FOR INSTALLATION WORK

4.1 Documentation

4.1.1 The Vendor/Contractor shall ensure that a detailed overall construction schedule is developed for the
installation to proceed in a controlled and orderly manner. The sequence of installation for major items must be
developed in order to ensure the correct and progressive utilisation of resources, man-power and craneage.
Normal practice shall be to work from the centre out and install the heaviest lifts first.

4.1.2 A full schedule of lifts shall be developed to insure that adequate craneage is pre-ordered to coincide with the
construction schedule. This listing shall be evaluated with the latest delivery schedule for critical and heavy
items. A careful study of all of the general arrangement drawings shall be conducted to determine required
craneage movement areas together with any lay down areas necessary to off load large and tall items of
equipment.

4.1.3 The Vendor/Contractor also shall be required to establish safe working procedures and shall submit these to
the Owner for approval. On large installations a formal Safety Officer will be appointed who will be the
nominated person for all safety matters whilst the Vendor/Contractor is on site.

4.1.4 A formal file shall be set up for each section of the plant with a complete set of construction drawings and
documents including the P&IDs, layouts, drawings, installation manuals, material certification data books, and
certification. The Vendor/Contractor shall ensure he is in possession of adequate design information, including
principal and critical dimensions, information required for support and foundation preparation, size and
location of all connections, nameplate information, dry weight and centres of gravity, operating weight,
location of lifting lugs, Vendor/Contractor's installation instructions, and as-built changes etc.

4.1.5 A schedule of tools and equipment for installation shall be prepared, together with man-power requirements to
execute the work.

4.1.6 All calibration certificates for test equipment, craneage and associated lifting equipment shall be obtained and
verified for any item before it is brought onto site.
 GENERAL ENGINEERING SPECIFICATION GES C.05
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4.1.7 A schedule of necessary work permits shall be drawn up to ensure they are in place at the required time.

4.1.8 The Vendor/Contractor shall be responsible for the preparation of procedures for the receipt, unpacking,
depreservation, and recording of defects, broken or missing parts, etc. Where the Purchase Order/Contract
includes temporary storage facilities these procedures shall also cover storage and inventory control.

4.2 Specifications and Manuals

4.2.1 The Vendor/Contractor is required to ensure all required specifications, codes and standards, installation
instructions and manuals are available and understood by the installation team.

5.0 MATERIAL CONTROL

5.1 Material Supply

5.1.1 The Vendor/Contractor shall supply all materials relative to his scope of work. This would normally be
consumable items such as sealants, grouting, temporary fasteners, welding electrodes, and other small items.
All such materials shall be of acceptable quality in accordance with the relevant specifications for the plant.

5.1.2 All structural steel, or piping materials that form part of the Vendor/Contractor's scope shall be new and
identifiable by means of certified marking relating to available, authentic material certificates. Where test
certificates cannot be obtained or verified, the Vendor/Contractor shall conduct all necessary and appropriate
tests in accordance with ASTM A6 - Specification for General Requirements for Rolled Structural Steel Bars,
Plates, Shapes and Sheet Piling.

5.1.3 Structural members, piping or plate materials found with surface defects such as embedded mill scale, cracks,
laminations, etc. shall be rejected if the defects exceed the allowable tolerances specified in relevant ASTM
standards or as directed by the Owner.

5.1.4 Where materials within the Vendor/Contractor's scope of supply, are not specified on the item data sheet or
relevant technical specifications, the Vendor/Contractor shall select materials using current ASTM standards
and inform the Owner before they are acquired.

5.2 Site Storage and Material Receipt

5.2.1 The Owner shall supply "Free Issue" to the Vendor/Contractor all equipment so listed in the Purchase
Order/Contract. The Vendor/Contractor shall provide a dust free weatherproof building for storage of
materials, equipment etc., where indicated in the Purchase Order/Contract.

5.2.2 The Vendor/Contractor shall take any further precaution deemed necessary by the Owner to protect the
material/equipment (during the period prior to installation) against corrosion or deterioration as defined in GES
C.01 and GES C.02.

5.2.3 The Vendor/Contractor shall limit the removal of equipment from its packaging to the minimum necessary to
verify that no physical damage was incurred during transit. Any defects or discrepancies shall be notified in
writing to the Owner. After inspection the equipment shall be repacked and preserved as defined in GES C.01
& GES C.02. Small items may be removed from packing cases if suitable storage areas are available.

5.2.4 The Vendor/Contractor shall determine the material quantities required from the design documents and
drawings.

5.2.5 The Vendor/Contractor shall be held responsible for the quality and suitability of those materials in his supply.

5.2.6 Materials used in construction shall be stored so that they are safe from damage by construction traffic and
deterioration by exposure to weather. In areas where corrosive salts are present in the atmosphere, the steel
 GENERAL ENGINEERING SPECIFICATION GES C.05
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components shall be stacked on supports at least 3.25 ft (1 m) clear of the ground. Under no circumstances
shall steel be stored directly on the ground.

5.2.7 For larger items of equipment the Vendor/Contractor shall co-ordinate their delivery onto the site in
conjunction with the required craneage.

5.2.8 Machinery which is in the normal capacity of craneage on site may be off-loaded in a marshalling area so that
it may then be called off for installation when required.

5.2.9 For very heavy items the logistics of receiving them onto the site and the co-ordination of heavy lift cranes
shall be planned well in advance of delivery. All required resources shall be mobilised with the minimum of
time loss. The foundation shall have been inspected and shall be ready to receive the item. All heavy lift
equipment shall be off-loaded and installed at the same time where possible.

6.0 SAFETY

6.1 Policy and Procedures

6.1.1 The Vendor/Contractor shall be required to submit details of how he will meet the safety policies of the Owner
outlined in GES C.03 prior to commencing work.

6.1.2 The Vendor/Contractor shall develop a schedule of work permits necessary for the Purchase Order/Contract
and ensure these are in place before attempting to start any new activities. All necessary safety equipment and
protective clothing shall be provided.

6.1.3 Refer to Section 4.1.3 regarding safe working procedure and Safety Officer.

7.0 FOUNDATION INSPECTION

7.1 The Vendor/Contractor shall carry out a detailed inspection of all foundations prior to installation of large
equipment to ensure they are suitable for accepting the items and assure himself that there are no problems that
will interfere with the installation. The foundation shall have been constructed in compliance with GES Q.03.

7.2 The foundation shall be checked to confirm the height and overall dimensions of plinths, mountings, rails,
sumps and supports. Any evidence of exposed reinforcing bars, incorrectly compacted concrete, cracks,
separations, sand and dirt traps, misalignment, under and over fills, incorrect levels etc., shall be cause for
rejection of the foundation.

7.3 The location of all anchor bolts shall be confirmed. The foundation shall be checked for dimensional accuracy
against the drawing or template if one was provided.

7.4 Anchor bolts and slide rails already cast in-situ shall be fully checked for size, type, alignment and damage.
Each bolt and rail shall be cleaned and threads checked using a correct size nut. All threads shall be coated
with anti-seize compound. Rails shall be cleaned and greased if so specified on the drawing.

7.5 The surface of the foundation shall be coated where specified on the drawings. Where anchors are to be
placed after installation at the location, the size and depth of anchor wells shall be checked.

8.0 INSTALLATION OF MAJOR ITEMS

8.1 Prior to the installation of major items the Vendor/Contractor shall ensure adequate craneage is available
together with all materials, slings, labour and skilled supervision. This shall be mobilised only after the
Vendor/Contractor has confirmed the delivery time of the equipment to its lifting location.
 GENERAL ENGINEERING SPECIFICATION GES C.05
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8.2 The base plate of the equipment shall be checked against the details recorded for the foundation. Where a
template has been used to check the foundation anchor points this shall be used to verify the base plate.

8.3 The Vendor/Contractor shall be responsible for determining the required area of operation for craneage.
Adequate areas are to be cleared to allow for slewing the crane. A plan of craneage required and slewing
requirements shall be drawn up and presented to the Owner for approval.

8.4 The Vendor/Contractor shall ensure that the equipment can be correctly located onto its foundation. Any
discrepancies found shall be resolved with the Owner.

8.5 The equipment and appropriate craneage shall be marshalled to the lifting area. Any packing that will interfere
with the locating of the item may be removed but all flange protection, stops, stays, and other temporary
protection shall remain in place.

8.6 The Vendor/Contractor is responsible for determining with the Crane Supervisor how the item is to be lifted.
Where there are pre-determined lifting eyes these shall be inspected for adequacy and used for the lift. The
manufacturer's data shall be referred to for any installation recommendations including lifting instructions.

8.7 Lifting shall be carried out using slings correctly sized for the task and protected where necessary to prevent
damage. Any lifting frames supplied with the equipment shall be used. Failure to do so may jeopardise any
warranty claims. Spreader bars and other lifting devices shall be correctly sized and appropriate to provide an
even lift.

8.8 Prior to setting the unit onto its foundation the Vendor/Contractor shall be responsible for making sure the
foundation itself is clean and that the base of the unit is clear of any debris or damage. Where necessary the
base of equipment shall have its paintwork repaired before being lowered onto the foundation.

8.9 Once located the unit shall be lined, levelled and plumbed in accordance with project specifications. Any
variation from specified requirements shall be reported to the Owner for resolution.

8.10 The Vendor/Contractor shall be responsible for ensuring heavy lift craneage is available when required and
released quickly with the minimum number of mobilisations practical to execute the work.

9.0 FIXING AND GROUTING

9.1 Rods and Anchor Bolts

9.1.1 These elements shall be either:

- sealed directly at the concreting time;

- preferably set in the reserved holes.

9.1.2 In the first case the adjustment shall be ensured by the use of templates rigidly held, enabling solid embedment
and guaranteeing that there shall be no movement during placing of concrete.

9.1.3 In the second case, the seal shall be made after adjustment and clamping of anchors. The sealing mortar shall
be of non-shrinking type with a high cohesion capacity. The characteristics of this mortar and the procedure
for its implementation shall be approved by the Owner.

9.1.4 Anchoring systems by means of self-drilling and/or self-blocking bolts may be used. The types envisaged for
use shall be approved by the Owner.

9.1.5 The embedment for the various types of anchor shall depend on the nature and the amount of force to be
transferred to concrete and shall be approved by the Owner.
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9.2 Grout Mix Design

9.2.1 The sand-cement mix shall be such that the compressive strength of the grout at seven (7) days shall be not less
than 4,000 psi (28 N/mm2) as determined by tests on 2 in (50 mm) cubes.

9.2.2 The water-cement ratio shall not be greater than 0.50 by weight and the grout mix shall have limited fluidity as
agreed with the Owner. Neat cement grout shall not be used.

9.2.3 The cement : sand mix shall be 1 : 1 for bedding thicknesses not greater than 1 in (25 mm) and 1 : 2 for
bedding thicknesses not greater than 2 in (50 mm). Where bedding thicknesses are greater the mix shall be in
accordance with the drawing and/or the Owner's instructions.

9.2.4 Other special grout, e.g. rapid hardening or quick setting, epoxy grout shall only be used with written
agreement from the Owner and to an agreed specification.

9.3 Mixing, Placing, Curing and Testing

9.3.1 Grout shall be mixed adjacent to the area being grouted and sufficient manpower, materials and equipment
shall be available for rapid and continuous mixing and placing.

9.3.2 After mixing is completed, the grout shall not be remixed at any time for any reason. Mixing water above
80oF (27oC) shall not be used.

9.3.3 Placing of grout shall be at the lowest practical temperature, preferably between 45-90°F (7 - 32°C), for
foundations, base-plates and grout material. The temperature shall be maintained within this range for 24
hours following installation and thereafter above 40oF (4oC) until strength exceeds 4,000 psi (28 N/mm2).
Cold water shall be used to extend working time in hot weather.

9.3.4 Care shall be taken to ensure that the grout completely fills the void to be grouted and is thoroughly compacted
and free from air pockets. Any areas or pockets which are to be kept free of grout shall be sealed with an
approved material. Grout may be placed by either pouring or pumping.

9.3.5 Grout placed by gravity flow shall be applied continuously under a head of not less than 1¼ in (30 mm) and
worked until the space is completely filled. Vibration shall not be used.

9.3.6 The grout shall not be overworked. All bolt holes and sleeves shall be adequately filled and pressure grouting
used where directed by the Owner. The grout shall be properly and adequately cured before operation of
equipment.

9.4 Finishing of Grout

9.4.1 After an initial set has taken place, the work shall be neatly pointed and trowelled off and left in a workmanlike
manner. Exposed edges shall be protected against damage during the curing period.

9.4.2 Where shims are to be removed, or if wedges were used, they shall be removed after three (3) days. On
removal of the shims or wedges, the resultant spaces shall be filled with grout. Foundation bolts shall then be
pulled for tightness.

9.4.3 Where drawings specify painting of grout, this shall be applied when grout is completely dry.

10.0 STEELWORK ERECTION

10.1 General

10.1.1 Erection work shall be permitted only after the foundation or other structure over which steel work is to be
 GENERAL ENGINEERING SPECIFICATION GES C.05
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erected has been approved and accepted by the Owner. The Vendor/Contractor shall satisfy himself about the
levels, alignment etc. for the foundation well in advance, and before starting the erection. All fabrication steel
shall be true in its designated location with members plumb and level.

10.1.2 Steel base plates shall be welded, shimmed or supported at the required elevations, so that they are set level
and true, and left for grouting. Temporary bracing shall be provided during erection of steel as required for
proper alignment and stability of the framing assembly. The bracing members shall be superimposed to allow
for any forces that the structure may be subjected to while construction operations are underway.

10.1.3 Any faulty erection carried out by the Vendor/Contractor shall be made good at his own cost. Approval by the
Owner shall not relieve the Vendor/Contractor of any of his guarantees under the Purchase Order/Contract.

10.2 Marking

10.2.1 All fabricated steel sections will have been match marked at the fabricators for field assembly using designated
numbers or letters corresponding to the field erection drawings. Match marking of steel is carried out with
waterproof ink or with pressed metal tags. The Vendor/Contractor shall be responsible for ensuring assembly
is conducted in accordance with the match marking details.

10.3 Handling

10.3.1 Shop or field fabricated structural steel shall be handled in such a manner as not to damage parent material or
paint. If doubt exists concerning damage during erection, slings shall be padded with hardwood slats or other
approved material.
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10.4 Erection Stresses

10.4.1 As erection progresses, the work shall be securely bolted, or welded, to minimise all dead loads, wind and
erection stresses. Wherever piles of material, erection equipment or other loads are carried during erection,
proper provision shall be made to minimise stresses resulting from such loads.

10.5 Installation of Grating

10.5.1 Grating shall have a minimum bearing of 1 in (25 mm) on supporting structural members. Grating shall be
installed with cross-bars on top and fastened as shown on drawings. Erection clearances between adjacent
panels shall be ¼ in (6 mm) between ends of cross bars and _ in (9.5 mm) between ends of bearing bars.
Bearing bars and cross bars of adjacent panels shall be in line. Welding to the supports shall be as specified on
drawings. All cuts shall be bonded as detailed.

10.6 Installation of Floor Plates

10.6.1 Floor plates shall be installed with a minimum of two opposite edges resting on the centreline of the supporting
steel as detailed on drawing. Plates of two or more spans shall be plug welded to the intermediate supports.
Plates on floors to be dustproof shall be welded continuously along all floor seams.

10.7 Tolerances

10.7.1 Generally all the allowable tolerances shall be as per AISC specification and standard. However,
notwithstanding the tolerances mentioned in above codes the following tolerances shall apply:

Maximum deviation from intended line ± ¼ inch (6 mm) in 20 ft (6 m).

Maximum deviation of length of diagonal (out of square) ± ¼ in (6 mm) in 20 ft (6 m).

Maximum deviation from intended length of member with both ends finished for contact bearing ± 1/16 in (1.5
mm).

Maximum deviation from intended length ± _ in (3 mm).

Maximum deviation from verticality (out of plumb) ± _ in (3 mm) in 20 ft (6 m).

11.0 INSTALLATION OF ROTATING EQUIPMENT

11.1 The machinery alignment will be made in accordance with the requirements as detailed in the equipment
installation, operating and maintenance manual.

11.2 Major items of rotating equipment e.g. turbines, compressors, pumps, will have alignment procedures and
applicable tolerances set by the manufacturer. The Vendor/Contractor shall adhere to these unless notified
otherwise by the Owner. In those instances, alignment adjustment will normally only be made in the presence
of or under the direction of the equipment manufacturer's Engineer.

11.3 In order to permit alignment to be carried out, the Vendor/Contractor shall be responsible for the removal and
replacement of any work, e.g. coupling guards and couplings.

11.4 Where the manufacturer has not specified specific alignment procedures or on minor items of rotating
equipment, the tolerances stated by the coupling manufacturer will apply.

11.5 It shall be the Vendor/Contractor's responsibility to ensure that the work site is maintained in a clean condition,
especially when equipment is being worked on, that all machine nozzles are protected from the ingress of
foreign matter, and exposed machinery surfaces are treated with preservative. If for any reason the Owner or
 GENERAL ENGINEERING SPECIFICATION GES C.05
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the Inspector has doubt on the internal integrity of a rotating machine due to on-site work practices, it will be
opened for inspection.

11.6 The Vendor/Contractor shall complete and record all readings taken for the coupling on each item of
equipment as indicated below.

11.7 Normally, the alignment for the three conditions listed below shall be recorded on three separate sheets for
each coupling.

A - Base Plate Holding Down Bolts - Loose, Piping Flange Bolts - Loose.
B - Base Plate Holding Down Bolts - Tight, Piping Flange Bolts - Loose.
C - Alignment - Driven Machine, Base Plate Holding Down Bolts - Tight, Piping Flange Bolts - Tight

Readings may be witnessed by the Owner or the Inspector, however the acceptance signatures will not be
given until satisfactory alignment conditions are met.

11.8 Where satisfactory alignment is achieved above, but subsequently is changed, for example, due to incorrectly
installed or modified pipework, the Vendor/Contractor shall repeat the machine alignment to bring it back to a
satisfactory condition. The original test sheet will be rejected and replaced by new sheets signed by the
Vendor/Contractor.

11.9 The following guidelines should be used for the procedure and tolerances whilst making an alignment, if not
quoted by the equipment manufacturer.

11.9.1 Machine Conditions

Coupling Hub Runout: Prior to checking alignment the coupling hub runout shall be checked by mounting
the magnetic base of the dial indicator on each hub in turn and placing the dial indicators against the coupling
periphery and face, keeping the hub on which the magnetic base is mounted, stationary and rotating the hub
under the dial indicator.

Tolerances - Coupling Periphery - Roundness

Maximum 0.005 in (0.125 mm)
- Coupling Periphery - Squareness
Maximum 0.005 in (0.125 mm)

11.9.2 Alignment, Base Plate Holding Down Bolts - Loose, Piping Flange Bolts - Loose

To be carried out by rotating both the driver and driven shafts together. If this is not possible the alignment is
to be made by mounting the magnetic base of the dial indicators rigidly to the most easily rotated machine
shaft, and rotating these around the stationary shaft and hub. Readings shall be taken at 0o (dial indicators
zero), 90o, 180o and 270o positions.

Where there is coupling hub "runout" on the hub being checked, the position of maximum runout should be
placed across the 90o - 270o position. Driven machine suction and discharge pipework shall be supported and
must impose no load on the machine nozzles. Parallelism reading may be taken with an inside micrometer or
gauges.
Tolerances - Coupling Periphery Alignment
Maximum 0.005 in (0.125 mm)
- Coupling Face Parallelism
Maximum 0.005 in (0.125 mm)

11.9.3 Alignment, Base Plate Holding Down Bolts - Tight, Piping Flange Bolts - Loose

The alignment shall be made as for condition 11.9.2. The readings shall be taken and recorded before and
after tightening the holding down bolts, readings should not change by more than 0.001 in (0.025 mm) in any
direction. The alignment tolerance will remain the same.
 GENERAL ENGINEERING SPECIFICATION GES C.05
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11.9.4 Alignment, Base Plate Holding Down Bolts - Tight, Piping Flange Bolts -Tight

The alignment shall be made as for condition 11.9.2. The readings shall be taken and recorded before and
after tightening the suction and discharge flanges. Machine alignment should not change by more than 0.001
in (0.025 mm) in any direction. The final alignment should remain within the specified tolerance.

11.10 On completion of the machine alignment the Vendor/Contractor shall install the coupling guard. When the
Owner or the Inspector is satisfied, the Vendor/Contractor may remove the coupling spacer, if so specified to
prevent accidental operation, and place it in the Owner's custody.

12.0 CONNECTIONS AND BOLTED ASSEMBLIES

12.1 Field Connections

12.1.1 Field connections for permanent floor plates and random length material for handrailing assemblies shall be
welded. Bevel washers shall be furnished for all bolted connections to sloping flanges. High strength bolted
connections shall be designed as bearing type connections with bolt threads in shear planes. High strength
bolts shall be tightened using torque wrenches set to the specified torque requirements.

12.1.2 High strength bolted parts shall fit solidly together when assembled and shall not be separated by gaskets or
any other interposed compressible materials when assembled. All joint surfaces, including those adjacent to
the washers, shall be free of scale except tight mill scale. They shall be free of dirt, loose scale, burrs and other
defects that would prevent solid seating of the parts. Contact surfaces within friction type joints shall be free
of oil, paint, lacquer or galvanising.

12.2 Bolted Assemblies

12.2.1 Round Holes - Holes for bolts shall be 1/16 in (2 mm) larger than the nominal diameter of the bolt or as shown
on the drawings. Holes shall be drilled or sub-punched and reamed. Torch cutting of holes at any time is not
permitted.

12.2.2 Slotted holes shall be in accordance with the AISC specification for Structural Joints ASTM A325 or A490
bolts.

12.2.3 Mating Surfaces - Surfaces of bolted parts in contact with bolt heads and nuts shall not have a slope of more
than one to twenty (1:20) with respect to a plane normal to the bolt axis. Bolted parts shall fit solidly together
when assembled and shall not be separated by gaskets or any other interposed compressible material. Where
the surface of a bolted part has a slope of more than one to twenty (1:20), a bevel washer shall be used to
compensate for non-parallelism. All joint surfaces shall be free of scale, dirt, burrs and other defects that
would prevent solid seating of the parts.

12.2.4 Installed and spare bolts and nuts shall be new, cadmium plated (plus full passivation) and coated with an anti-
seize compound when assembled.

12.2.5 Termination points for connections to skid mounted equipment shall be at the edge of the skid and manifolded,
where possible to provide the minimum number of connections. The Owner's or the Vendor/Contractor's
piping design will consider such terminations to be rigid anchors. The maximum allowable forces and
moments which can be applied to terminations will have been determined by the manufacturer. It is the
responsibility of the Vendor/Contractor to ensure no undue stresses are applied to the unit by incorrect
fabrication practices such as misaligned pipework being forced into position.

13.0 WELDING

13.1 Introduction
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13.1.1 Welding procedure specifications for all joints shall be in accordance with the requirements of the design code
and GES W.01 and shall be submitted, together with relevant procedure qualification records for Owner's
review. No welding shall be performed until the welding procedures and the qualifications records of the
proposed welders/operators have been approved.

13.2 Welding Procedure Qualification

13.2.1 It shall be the responsibility of the Vendor/Contractor to formulate and physically qualify welding procedures
for each of the types of material anticipated for use in site fabrication activities. These procedures shall be
submitted to the Owner or his representative for approval and shall include details regarding welding
procedures, filler metals, fluxes, preheat and post-heat requirements, stress relief and separation of abutting
joints. Approval of welding procedures by the Owner shall not relieve the Vendor/Contractor of his
responsibility to produce the quality of welding necessary to satisfy all aspects of the Purchase
Order/Contract.

13.3 Welding Codes

13.3.1 All welding shall be done in accordance with codes of the American Welding Society or equivalent codes and
standards. Surfaces to be welded shall be free from loose scale, slag, rust, grease, paint and any other foreign
material. Joint surfaces shall be free from fins and tears. Preparation of edges by gas cutting shall, wherever
practicable, be done by a mechanically guided torch. All butt welded joints shall have full penetration. Welds
between members jointing at right angles to each other shall not be considered as butt welds.

13.4 Preheating

13.4.1 Base metal shall be preheated as required to the temperature called for in the approved welding procedures.
Preheating shall be checked by a recognised method such as thermocouple or thermocrayons.

13.5 Residual Stresses

13.5.1 In assembling the joining parts of a structure or of built-up members, the procedure and sequence of welding
shall be such as to avoid needless distortion and minimise shrinkage stresses. Where it is impossible to avoid
high residual stresses in the closing weld of a rigid assembly, such closing welds shall be made in compression
elements.

13.6 Stress Relieving

13.6.1 When required by welding procedures, welded assemblies shall be stress relieved by heat treating in
accordance with the provisions of the welding specifications.
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14.0 INSULATION

14.1 Equipment and pipework shall be insulated for heat conservation as required and detailed in GES N.01 and
GES N.02, provision is to be made for personnel protection for all accessible surfaces operating at or over
140°F (60°C). The Owner or the Vendor/Contractor shall provide the appropriate drawings giving the extent
of equipment and pipework to be insulated for heat conservation or noise reduction. Noise reduction shall be
achieved by insulation in accordance with GES N.03. The Vendor/Contractor is responsible for making good
all insulation damaged or removed during the installation process.

15.0 PAINTING

15.1 Equipment, pipework and structural steel shall be prepared and painted using the appropriate coating system
selected from GES X.01, GES X.02 and GES X.03.

15.2 All external surfaces shall be painted including inside surfaces of skirt supports, inside bolt holes and edges of
flanges up to the gasket facing.

15.3 Stainless steel and galvanised equipment and structures shall not be painted unless specified by the Owner.

15.4 The Vendor/Contractor is responsible to make good all paintwork damage during the installation process.

16.0 INSPECTION AND TESTING

16.1 General

16.1.1 The Vendor/Contractor shall be mainly responsible for the installation of all mechanical equipment and its
appurtenances, e.g. pipework, base plates, instrumentation, electrical equipment, cabling, etc.

16.1.2 For major mechanical equipment the manufacturer is normally responsible for his own equipment in terms of
set-up, alignment, inspection and approval. In turn the commissioning, start-up and performance testing may
be carried out by the Owner or a joint commissioning team may be set up for this purpose.

16.1.3 The Vendor/Contractor will assist in commissioning and start-up depending on his scope of work. The
inspection and testing programme will be incorporated into the overall plant pre-commissioning,
commissioning and start-up dossier. Although the Vendor/Contractor's scope of work may include for
construction, testing and pre-commissioning under a main construction contract; the commissioning and start-
up activities may form a separate contract. Individual equipment is to be inspected as per the Purchase
Order/Contract. All work carried out by the Vendor/Contractor is subject to approval by the Owner.

16.1.4 Any approvals given do not relieve the Vendor/Contractor of any responsibility regarding guarantees,
workmanship or compliance with internationally recognised codes of practice and the relevant specifications.

16.1.5 Following installation, the Vendor/Contractor shall be responsible for carrying out a pre-commissioning
inspection on all equipment that is within the scope of the Purchase Order/Contract as defined in the following
sections. The installation is to be checked against the latest revision of the P&IDs, drawings and other
documentation.

16.1.6 All findings that are not in accordance with drawing shall be resolved to one of the following options:

a) rework to restore correct conditions;

b) confirm installation is satisfactory and fit for the purpose. Details to be noted and as-built drawings
prepared for the Owner's approval.

16.2 Operational Preliminary Checks

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On construction only projects the Vendor/Contractor does not have responsibility for the engineering of the
plant but should bring details of defects found to the Owner's notice. On EPC contracts the Vendor/Contractor
will be responsible for any defects found in the plant.

16.2.1 Manually Operated Valves

Are these valves accessible? Not too high or too low.

Are they positioned in a safe manner, especially when open and the spindle protrudes fully?
Are there any manually operated valves which are frequently used but are inaccessible, i.e. in a pipe rack.

16.2.2 Locally Mounted Instruments

If a pump discharge line is provided with a local flowmeter, is it easily visible whilst opening or closing the
pump discharge valve?
Are solenoid valve reset levers accessible?
Are locally mounted instrument displays / meters easily visible?
Where gauge glasses are provided, check that they can be easily read and able to be blown down.

16.3 Piping Preliminary Checks

16.3.1 General

Check that the correct materials of construction have been used. Where specified in the Purchase
Order/Contract, record actual heat numbers from materials.

Check that vents, bleeds and all other items are as shown on the P&ID or isometric.
Confirm all tag numbers, pressure ratings and types of equipment are correct.

16.3.2 Non-return Valves, Control Valves, Certain Globe Valves

Ensure these are installed with the flow direction arrow (stamped or tagged on the valve body) in the correct
direction.

16.3.3 All Valves

Check that packing followers are correctly tightened and that the valves open and close smoothly.

16.3.4 Sample Connections

Are these correctly placed, i.e. not in a dead-end?

Are they of the type indicated on the P&ID, i.e. double valve, block & bleed, needle etc.
Is there room enough to insert the sample bottle?
Are sample coolers correctly piped up?
Are the sample points clearly identified as such with clear reference to the chemical hazards that will exist?

16.3.5 Pump Suction Strainers

Can the strainer body be depressurised and drained?

Can a drain hose be coupled to the drain connection without problem?
Is there enough room to insert a bucket or can underneath the drain port?
Can the strainer be removed without problem?

16.3.6 Spectacle Blinds

Can they be swung easily?

Are they installed in such a way that they can be swung without a shutdown, i.e. between double block and
bleed valves.
 GENERAL ENGINEERING SPECIFICATION GES C.05
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16.3.7 Piping Low Points, High Points and Slopes

Check these are in accordance with the P&ID.

16.3.8 Pipe Supports

Check spring hanger transit pins have been removed.

Check slipper pads are situated correctly in their guides.
Check pipe clamps are tight.

16.3.9 Steam Traps

Check these are correctly installed and that they blow to a safe location.
Check integrity of isolation and bypass valves.

16.3.10 Safety Valves

If these vent to atmosphere, check that the exhaust line is adequately supported.
If paired safety valves with a key lock system are installed, check the lock system is in good order.
Confirm if there is evidence of testing and calibration. Where seals are required have they been fitted?

16.3.11 Insulation

Check that piping insulation on hot and cold service lines is in good condition and has been completed. In
some cases insulation may not be completed until just prior to start-up. This is to be added to a completion
punch list.

Check that the insulation cannot become saturated with water during flushing operations or inclement weather.

16.3.12 Earthing

In some piping applications flanges are coupled by an earthing strap, check integrity of strap and connections.

16.3.13 Gaskets & Joints

If soft metal ring joint flanges are installed, ensure that a check has been carried out of flange face integrity.
This type of flange/joint is often used in hot, high temperature service such as catalytic reformer reactor
inlet/outlet flanges. Where spiral wound gaskets are employed it is important to check that the correct rating
has been employed.

If pipework is to be dismantled for flushing, this type of gasket is frequently replaced temporarily by an
asbestos compound gasket. The correct gasket must be installed prior to handing over the system for start-up.

16.3.14 Blinds

A blind list shall be prepared. It is most important to initiate a blind list at the earliest possible opportunity.
The reasons for a blind list are as follows:

- to record where the blinds are situated and why;

- to ensure that the blinds are removed prior to start-up.

In the case of spectacle blinds and certain other blinds, it may well be necessary that these remain in position at
the time of start-up, however, a battery limits blind list shall be issued prior to start-up in order that blind status
may be readily checked.
 GENERAL ENGINEERING SPECIFICATION GES C.05
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It is often the case that blinds are installed during construction and pre-commissioning, for hydrostatic test,
flushing etc., and these are frequently forgotten if not correctly listed. It is also not unknown for blinds
without tags (handles) to be installed, in this case it is extremely difficult to tell the difference between a blind
and the edge of a spiral wound metal gasket. Therefore blinds shall always have a tag or handle which should
be painted red for easy identification.

16.4 Vessels Preliminary Checks

16.4.1 A preliminary check of vessels is required prior to handing over to the pre-commissioning team. To this end
the following items of equipment are considered as vessels:

Towers distillation columns, splitters, strippers, absorbers etc.

Drums overhead receivers, HP & LP separators, oil / gas separators, knockout drums, surge drums, flash
drums, balance drums, instrument air dryers, molecular sieves, steeling drums, contactor drums,
desalters.

Boilers, Steam Generators of all types, Reboilers.

Furnaces all types including combustion type inert gas generators, Klaus process sulphur recovery units etc.

Storage Tanks all types.

Underground Tanks / Sumps all types, steel or concrete.

Oily Water Separators

Heat Exchangers shell and tube, kettle type, plate exchangers, vaporisers.

Pig Receivers and Launchers

Desalination Units

16.4.2 External Checks

- check maker's nameplate details are correct;

- check access ladders and platforms are correctly installed and in good order;

- check nozzles and manways are as shown on updated P&ID and engineering drawings;

- check integrity of insulation;

- ensure fire detectors, sprinklers, deluge systems, foam heads are correctly installed;

- carefully inspect the outer skin of pressure vessels to ensure that at no time has any unauthorised
welding taken place. Sometimes scaffolding is temporarily tack welded in place by mistake. Most
pressure vessels are marked "NO WELDING" to avoid such mishaps but nevertheless one can never
discount human error. If such a case is discovered, the vessel in question shall be subjected for
rectification, i.e. stress-relieving, non-destructive testing etc.

16.4.3 Internal Checks

NOTE: Before entering any vessel the person responsible shall obtain a vessel entry permit; the vessel will
also be subjected to an atmospheric analysis for oxygen. Additionally suitable means of entry and exit
shall be provided. Vessels which may contain toxic vapours, i.e. following the application of an
 GENERAL ENGINEERING SPECIFICATION GES C.05
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internal lining medium such as epoxy resin must be given special consideration with respect to
personal protection equipment and safety hazards.

If the vessel is in any way physically connected to a “live” system it must be suitably blinded and details added
to the blind list.

All vessel inspections shall be based on equipment design drawings.

All vessels, verify the makers nameplate details are correct and verify all nozzles are correctly sized and
oriented.

In situations where manways are specified in trays or baffles in particular vessels, a check must be made to
ensure that these manways are in fact installed with appropriate bolting and gaskets, as specified on the
drawings.

16.4.4 Towers, Columns

Carry out a documentary check that all internals, such as trays, weirs, impingement plates, distributors etc.
have been installed correctly and checked off. Should an anomaly exist vessel entry will become necessary for
inspection and rectification.

All towers and vessels are to be clean and free of any debris, excess rust etc. For the most part this will require
hand cleaning.

Final inspection of all towers and vessels will include a check for manway gaskets of proper size and
materials, and that manway stud / bolts are properly tightened.

Verify types of trays and types of valves in tray deck.

Check tray support rings for welding and dimensions.

Check to make sure that tray valves are not corroded or stuck.

Check downcomers for proper vertical alignment and clearance between bottom of downcomer and deckplate.

Check tray overflow weirs for proper dimensions and welding bolting.

Check bolting of tray segments to support rings - these must be tight and in some cases the underside nuts
require tack welding. Verify this against the drawings.

Check tray decks, tray valves and all internal bolting for proper materials of construction. Bolting must also be
checked for proper size and installation of washers. Verify tower / vessel material of construction.

Check each tray deck for horizontal deflection. Decks should be flat within a tolerance of ± ¼ in (6 mm),
measured across the diameter.

Check that splash weirs are installed and that they are properly secured by bolting or welding as per the
drawings.

Verify that required tray gaskets are properly installed and that they are of the proper materials.

Verify that all nozzles are open from the inside of the tower and that they are not plugged or restricted with
foreign articles, dirt etc.

16.4.5 Reboilers

Make sure that the reboiler feed nozzle is on the proper side of the baffle. Verify that reboiler return nozzle is
 GENERAL ENGINEERING SPECIFICATION GES C.05
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on the opposite side from reboiler feed nozzle. Verify against drawings.

Check appropriate design drawings on the involved tower or vessel and make sure of the baffle design details.
As an example, perforated baffles must not be installed in the bottom or reboil section of the tower.

Check that proper size weep-holes are drilled in the bottom of the seal pans, according to the drawings.

Check for installation of vortex breakers, as per the drawings.

16.4.6 Drums

Check especially that wire mesh pads, vortex breakers, weirs, baffles and other internals are in place and that
they are securely attached and of the correct dimensions.

16.4.7 Boilers / Steam Generators

Check that steam drum internals such as cyclones, baffles etc., have been securely installed. In boiler
fireboxes check the integrity of the refractory brickwork, burner quarls, baffle walls and so on.

Steam drums are to be inspected for cleanliness, installation of flood nipples, proper installation, bolting and
materials of construction of steam distributors, check that nozzle openings are not plugged or restricted etc.
The inspection of steam drums will be based primarily on the Vendor/Contractor's drawings.

Deaerator inspections are to include a physical inspection of the internals in the scrubbing section for
installation of trays, gaskets etc. There have been cases where trays have been found missing or dislodged,
internal nozzles missing, gaskets missing etc. The lower section of deaerators are to be inspected for proper
internals, nozzle openings, cleanliness etc.

16.4.8 Furnace & Ducting

Ensure furnace and burner refractory brickwork are in good order. Check ductwork refractory condition
(normally sprayed on cement coatings such as "GUNNITE"). Ensure all wooden framework used for castable
refractory is removed and no obstructions are present in the ducting or stack. Check furnace tube hanger
integrity. Ensure free movement of stack dampers, check furnace tube hydrostatic test has been completed.

16.4.9 Storage Tanks

- Floating Roof Tanks

Check the roof integrity. Ensure articulated roof drainlines are in good order.

- Cone Roof/Flat Roof Tanks

If a special lining has been applied on site such as epoxy, check that the combined vacuum
breaker/relief valve has not been affected, ensure nozzles and drain lines are clear. For tanks
containing demineralised water, an inspection report of the tank lining shall be required.

- Underground Tanks/Slumps

For steel tanks an external coating inspection is required. Check integrity of reinforced concrete
structures.

16.4.10 Heat Exchangers

- Shell & Tube Exchangers

Carry out a documentary check that these have been inspected internally for the removal of
 GENERAL ENGINEERING SPECIFICATION GES C.05
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preservatives and desiccants such as silica gel bags.

Exchangers delivered by sea may have had their tubes filled with grease or other preservatives, be
certain this has been removed prior to handover for commissioning.

- Plate Exchangers

Ensure correct installation following the Vendor/Contractor's instructions.

- Kettle Type Exchangers/Vaporisers

Many of these exchangers have internal baffles or weirs, check that these are correctly installed.

- Pig Receivers & Launchers

Check these are in good order and the pre-commissioning teams have carried out all necessary
checks, i.e. removal of preservative, check door opening mechanisms etc.

16.5 Rotating Equipment Preliminary Checks

16.5.1 These checks are principally carried out on rotating equipment, pumps, compressors, gas turbines, diesel
engines etc. A suitably qualified rotating equipment specialist should carry out the preliminary checks. The
specialist should check, with the documentation available, that the items such as the following have been
completed.

The items listed are only examples and do not represent all of the tasks carried out during pre-commissioning.

16.5.2 Pumps

Check driver rotation. Couple pump to driver.

Carry out a cold alignment of pump and driver and furnish an alignment record.

Check pump suction strainer is installed.

Possibly install temporary mechanical seal or packing if the normal items are liable to be unsuitable for use
during flushing operations (if the pump is to be run during flushing). Check that the seal is installed correctly.

If the pump has an integral lube oil or cooling system ensure that the relevant pre-commissioning tasks have
been carried out.

16.5.3 Compressors

Ensure suction and discharge piping has been correctly installed according to the Vendor/Contractor's
requirements or recommendations.

Check that cold alignment and grouting have been carried out satisfactorily and that documentary evidence of
this is to hand.

Special tests for reciprocating compressors:

- check fit and clearance of bearings, connecting rod, crankshaft and cross-head slides;

- check run-out of piston rod and cross-head slides;

- check valve lift.

 GENERAL ENGINEERING SPECIFICATION GES C.05
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- check piston rod seal assembly.

Check that vent lines from seals and distance housings are free from obstructions and routed to safe location
when the compressors are in hydrocarbon gas service.

16.5.4 Gas Turbines

These machines will most often have been installed under supervision of Vendor/Contractor's representative
and the pre-commissioning documentation pertaining to this should be available.

If the gas turbine is to drive a compressor or pump the suction and discharge piping must have been aligned
and freed of stresses.

16.5.5 Air Fin Coolers

Check that the fan and driver have been correctly aligned and the fan pitch and clearance have been set.

Ensure shipping material etc., has been removed from the air intake hood and that the tube fins have been
checked for damage.

Check that hydrotest report is available and that all header box plugs have been tightened correctly.

16.5.6 Diesel Engines

Check that the engine and driven equipment have been aligned and a report has been furnished.

Check lube oil system has been filled with the correct grade of oil and that oil filters have been installed.

Check that the diesel oil system has been prepared correctly.

If the engine has a closed loop cooling system, check it has been filled with inhibited water. If cooling is
provided by the plant cooling water system ensure it is piped-up correctly. Check radiators and cooling fans.

Check correct installation of exhaust systems, especially insulation. Ensure turbochargers have been filled
with the correct grade of oil.

16.5.7 Miscellaneous Mechanical Equipment

Ensure the following items are checked:

Lifting Equipment

Cranes, travelling hoists, winches, chain blocks etc. Tested in the presence of an Insurance Inspector and/or
appropriate governmental authority. Ensure certificates have been issued and are correct.

Check over all miscellaneous equipment and ensure it is adequately lubricated and in operable condition.

Calibrate all weighing and measuring equipment (i.e. weighbridges) in their final field-installed positions.
Ensure a calibration record / certificate has been issued. Documentation should show that the equipment meets
the specified tolerance for accuracy over a full range of operation conditions.

NOTE: As an exception to the above, the Owner will arrange for independent calibration of weigh scales and
product meters for custody transfer where required by government regulations.

16.6 Electrical Preliminary Checks

16.6.1 Using the final documentation a suitably qualified electrical engineer/technician is to check that the system
 GENERAL ENGINEERING SPECIFICATION GES C.05
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installation tasks listed below were in fact completed.

Check condition of equipment, quality of installation and compliance with manufacturer's instructions, safety
rules, applicable codes, standards and good practice.

Carry out breakdown test on oil sample for transformers.

Perform preliminary tests with equipment de-energised including:

- insulation resistance measurement;

- di-electric strength tests;
- check electrical conformity of power and control cables;
- measurement of earthing resistivity.

Simulate operation of manual and automatic control circuits with power circuits de-energised.

Paint or tag all electrical apparatus (push button boxes, connection boxes etc.) according to project
specifications.

Check direction of rotation of electric motors (uncoupled). Check motor bearing grease packing, or oil
level/oil rings if applicable. Measure motor insulation resistance phase-to-phase and phase-to-ground.

16.7 Instrumentation Preliminary Checks

16.7.1 Instrumentation personnel are to ensure the following tasks were carried out during installation:

Check and calibrate all instruments prior to installation (including valves and switches and package unit
instruments).

Install instruments, check conformity, accessibility and free movement.

Check all instrument tag numbers (including orifice plates and flow nozzles).

Check continuity of transmission and identification of indication, control and alarm signals.

Perform continuity and insulation tests for electric cabling.

Check that all inline instruments (with the exception of control valves) were removed prior to hydrostatic
testing plus:

- isolating and disconnecting instrument impulse lines, to dp transmitters etc.;

- isolating level transmitters, switches and open drain lines.

That the requisite pressure test on instrument take-off piping, air piping and air tubing have been performed
and documented.

Reinstall instruments after pressure tests.

Install sealing fluids where required.

16.8 General Preliminary Checks

16.8.1 The inspection team shall satisfy themselves that the following general tasks have been carried out:

Conformity check of equipment and installations to the applicable specifications and drawings.
 GENERAL ENGINEERING SPECIFICATION GES C.05
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That all rust preventives, oil, grease etc. used to preserve equipment during the construction phase have been
removed.

Painting shall be complete enough so that an excessive amount of scaffolding is not left still standing in the
areas where the operators must work to start up the plant. Also, the number of painters still working in the
area shall not be excessive.

All fire proofing and main insulation shall be complete, i.e. all equipment piping, instruments, instrument leads
etc., requiring insulation for heat conservation or proper operation shall be covered so that start-up operations
will not be delayed due to freeze-up or excessive heat loss. Insulation required for personnel protection shall
also be complete.

In addition to the above, final insulation jacketing shall be complete enough so that there will not be an
excessive amount of scaffolding still standing in the areas where the operators must work to start up the plant.
Also, the number of insulators still working in the area shall not be excessive.

The operating area and platforms shall be free of debris, tools and extraneous materials which would impede
operation or cause an unsafe condition. All accessways shall be open for emergency vehicles.

Remove all temporary supports, bracing's, stops that were installed to prevent equipment damage during
shipping, storage and construction.

17.0 AS BUILT DRAWINGS AND REPORTING

17.1 As installation progresses the Vendor/Contractor is required to verify the drawings used for installation and
mark up any discrepancies found.

17.2 The discrepancies are to be marked in RED pencil or ink and reviewed with the Owner for approval.
Approved deviations will be submitted to the Vendor/Contractor for modification.

17.3 Throughout the installation process the Vendor/Contractor is required to keep a running check list of items to
be completed either prior to or after commissioning. Where installation spares have been provided (e.g.
filters), they must be used and notes made to ensure they are changed at the commissioning stage.

17.4 A record of blind flanges or blanking plates fitted must be maintained in order that everyone is aware that
blinds are fitted and must be removed at the commissioning stage. The same applies to temporary gaskets and
bolting.

17.5 Where instruments or other small items of equipment, have not been available this must be identified on the
checklist.

17.6 All checklist items must be handed over to the pre-commissioning team unless they are within the scope of
work for the Vendor/Contractor who will then be responsible for resolving them.

18.0 GROUNDING

18.1 Each item of equipment, whether supplied separately or as part of a skid mounted package shall be provided
with two grounding lugs, mounted diametrically opposite each other on the equipment supports.

18.2 Earth flanges, or removable covers shall be provided with suitable electrical bonding across the flanges.
 GENERAL ENGINEERING SPECIFICATION GES C.05
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S:\NOC9077\ADMIN\SPECIFICATIONS\C-SERIES\C-05\GESC05RF
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.06

ELECTRICAL INSTALLATION PRACTICES

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL
 Compiled by Teknica (UK) Ltd

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4
1.3 Data Sheets 5

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 6

3.0 DESIGN 7

3.1 Environmental Conditions 7

3.2 Codes and Standards 7
3.3 Area Classification and Ingress Protection 8
3.4 Alarm Systems - Site 8
3.5 Alarm Systems - Process 8
3.6 Accidents 8
3.7 Cables 9
3.8 Compressed Air 19
3.9 Conduit Installations 19
3.10 Communication and Fire Alarm Systems 21
3.11 Distribution Boards 22
3.12 Domestic Type Installations 23
3.13 Drawings 23
3.14 Distribution System (Owner's Site) 24
3.15 Earth Continuity 24
3.16 Earthing for Substations 25
3.17 Earthing for Protection Against Static Electricity 25
3.18 Earthing Protection Against Lightning 26
3.19 Erection of Specialist Equipment by Others 26
3.20 Erection of Miscellaneous Equipment 26
3.21 Electricity Supplies to Contractor’s Huts 27
3.22 Electric Tools and Their Supplies 27
3.23 Emergencies 27
3.24 Fixing of Equipment, Supports and Miscellaneous Steelwork 27
3.25 Explosion-proof Equipment 27
3.26 Ferrules 28
3.27 Good Housekeeping 29
3.28 Intrinsically Safe Equipment and Circuits 29
3.29 Inspection 29
3.30 Instrument Supplies 29
3.31 Instrument Control Room Panel Electrical Equipment 30
3.32 Lighting 30
3.33 Labels 31
3.34 Motors 32
 GENERAL ENGINEERING SPECIFICATION GES C.06
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SEC TITLE PAGE

3.35 Material: Collection, Storage, Safe-guarding and 34

Disposal of Surplus
3.36 Oxygen Rich Atmospheres 34
3.37 Push Buttons/Motor Control Stations 34
3.38 Portable Tools 35
3.39 Plant Hire 35
3.40 Painting 35
3.41 Programming 35
3.42 Restriction of Work 36

4.0 VENDOR/CONTRACTOR'S DATA 40

4.1 Vendor/Contractor's Responsibilities 40

4.2 Security & Safety 40

5.0 QUALITY ASSURANCE, INSPECTION TESTING & COMMISSIONING 41

5.1 Quality Assurance 41

5.2 Inspection Testing & Pre-Commissioning 41
5.3 As Built Drawings 43
 GENERAL ENGINEERING SPECIFICATION GES C.06
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification details the minimum acceptable standards applicable to installation practices for
electrical equipment. This specification mainly covers Low Voltage (LV) installations but where
appropriate it shall also apply to Medium Voltage (MV) equipment for preparation, inspection, testing,
installation and pre-commissioning.

1.1.2 The specification and applies to installations in refineries, onshore oil and gas installations and processing
plants and also covers the type of domestic electrical installations associated with control rooms, plant
offices, etc.

For specific items or packages, the Vendor/Contractor shall read this document in conjunction with the
applicable equipment specifications, relevant Vendor/Contractor equipment information (Installation,
Operation and Maintenance Manual) detailed design documents and Data Sheets.

1.1.3 This specification is generally based on ANSI/NEMA Standards. Compliance by the Vendor/Contractor
does not relieve him of his responsibility to install the electrical equipment in a manner suitable for the
specified purpose. Any exception from this or other relevant documentation must be authorised in writing
by the Owner as failure to do so shall indicate full compliance; any remedial work then necessary shall be
at the Vendor/Contractor's expense.

1.1.4 This General Engineering Specification will form part of the Purchase Order/Contract together with any
Data Sheets, drawings or other attachments.

1.1.5 The Vendor/Contractor shall adhere to any restrictions placed on the use of tools and equipment during
construction and must comply with all safety regulations and precautions specified by the Owners.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES A.06 Site Data

GES B.12 Heating, Ventilation and Air-Conditioning

GES C.01 Protection of Materials and Equipment During Storage

GES C.02 Protection of Materials and Equipment During Construction

GES C.03 Safety Procedures on Construction Sites

GES C.54 Commissioning of Microprocessor Based Instrument Systems

GES C.55 Field Installation, Calibration and Testing of Instruments

GES C.56 Electrical Commissioning

GES C.60 Plant Pre-Commissioning, Commissioning and Start-Up Guidelines

GES C.61 Installation, Operation and Maintenance Manual Guidelines

GES L.02 Power and Control Cables

GES L.15 Poles for Transmission Lines

 GENERAL ENGINEERING SPECIFICATION GES C.06
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GES L.19 Building Electrical Systems

GES L.20 Towers for Transmission Lines

GES L.22 Substation Layout

GES L.25 Grounding and Over-Voltage Protection

GES L.26 Plant Lighting

GES L.27 Electrical Requirements for Control Rooms including Wiring

GES L.31 Area Classification

GES L.34 Electrical Equipment in Contaminated Environments

GES L.35 Electrical Equipment in Hazardous Areas

GES Q.01 Earthworks (including Site Preparation, Pits and Trenches)

GES X.06 Factory Coatings for Electrical Equipment and Instruments

GES X.21 Cathodic Protection Equipment

GES X.22 Cathodic Protection Systems for Plant, Pipelines and Well Casings

1.3 Data Sheets

The technical data supplied by the Owner for Owner supplied equipment will be given on the associated
Data Sheets.

The Vendor/Contractor shall complete the relevant part of the Data Sheets with the remaining information
where relevant.

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Construction

This means all erection, installation, verification and testing. This shall be in accordance with the
requirements as shown on the approved drawings, specifications and Data Sheets.

Pre-Commissioning

The Pre-Commissioning phase shall include the two main types of field activities:

a) Systematic conformity checks, carried out on each item of equipment, component and installation
materials such as switchgear, transformers, cabling, instrumentation etc., to verify visually the
condition of the equipment, the quality of the installation, the compliance with project drawings
and specifications, manufacturers instructions, safety rules, codes, standards and good practice.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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b) Selected equipment static/de-energised tests, to ensure the quality of a number of critical
components. This 'cold' testing concerns all disciplines, e.g. cable insulation, earthing and
continuity tests, switchgear, transformers and all electrical equipment tests, calibration of
Instruments, machinery alignments, setting of safety valves etc.

It is assumed that the air/water cleaning, flushing and reinstatement of pipes and vessels is also
being effected at this time by others.

Low Voltage (LV)

A class of nominal system voltages less than 1000 V.

Medium Voltage (MV)

A class of nominal system voltages equal to or greater than 1000V and less than 100,000V.

For power cables, the power-frequency voltage between conductors for which the cable is designed.

U

For power cables, the power-frequency voltage to earth for which the cable is designed.

MS

Mild steel

BASEEFA

British Approvals Service for Electrical Equipment for use in Flammable Atmospheres

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
 GENERAL ENGINEERING SPECIFICATION GES C.06
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specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Environmental Conditions

3.1.1 External Environment

These conditions are fully detailed in GES A.06 and covers the principal conditions affecting the electrical
power and control equipment and cables including maximum and minimum ambient temperature, dust,
humidity and altitude etc.

3.1.2 Internal Environment

Electrical Equipment and Materials may be housed in enclosed, air-conditioned equipment rooms designed
and operated in accordance with GES B.12.

Temporary excursions from these limits e.g. during short term power failure, shall be ignored for the
purposes of equipment rating.

3.2 Codes and Standards

3.2.1 General

In general, the requirements specified herein are based on the ANSI/NEMA and other American Codes and
Standards, the most important of which are listed overleaf. Unless otherwise stated, equipment and
materials shall comply with these Codes and Standards.

Unless specified otherwise in the Purchase Order/Contract, the current editions of the codes and standards
at the time of order shall be used.

The Vendor/Contractor shall operate and supply certification for a Quality System complying with the
requirements of the ASQ Q9000 Series or BS EN ISO 9000, Part 1 (Design) Part 2 (Production)
and Part 3 (Test and Inspection).

3.2.1 US Codes and Standards

API/RP2003 Protection Against Ignitions Arising out of Static, Lightning and Stray Currents

ASQ Q9000 Quality Management and Quality Assurance

NFPA70 National Electrical Code

3.2.2 IEC and other Recommendations

When appropriate, equivalent International Standards which may be used as alternatives are listed below
and may be used with the prior approval of the Owner. Equipment and materials complying with IEC
Recommendations shall be at least equal to the requirements of this specification. The Vendor/Contactor
shall advise full details of any deviations to these requirements in his offer if IEC based standards are
utilised.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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BS 4568 Specification for Steel Conduit and Fittings with Metric Threads of ISO Form for
Electrical Installations.

BS 5501 Electrical Apparatus for Potentially Explosive Atmospheres

BS 6651 Code of Practice for Protection of Structures Against Lightning

BS 7375 Code of Practice Distribution of Electricity on Construction & Building Sites

IEC 79 Electrical Apparatus for Explosive Gas Atmospheres

IEC 60364 (BS 7671) Requirements for Electrical Installation (IEE Wiring Regulations)

IEC 60529 Degrees of Protection provided by Enclosures (IP Code)

IP Model Code of Safe Practice, Electrical Safety Code - 1991.

3.3 Area Classification and Ingress Protection

3.3.1 Area Classification

The Vendor/Contractor will follow the Area Classification requirements, in terms of Zone 0,1,2 and Safe
(Non-Hazardous) Areas in accordance with GES L.35. The Vendor/Contractor shall ensure that his key
personnel, (i.e. all supervisory grades) are conversant with the area classification drawings and fully
understand the requirements for electrical apparatus and installations in the classified areas.

3.3.2 Ingress Protection

IEC 60529 precisely defines the Ingress Protection offered to equipment by its enclosure against solid
bodies and moisture. The NEMA Code is now similar and for most installations, an enclosure of 'IP54' (As
defined in both codes) shall be the minimum standard for outdoor installations.

3.4 Alarm Systems - Site

The Vendor/Contractor shall ensure that all his personnel fully understand the procedure to be followed in
the event of any general alarm being sounded for the construction site (eg Toxic Gas Alarm, Fire Alarm).
Full information on the procedure to be followed will be communicated by the Owner to the
Vendor/Contractor before the commencement of the electrical installation.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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3.5 Alarm Systems - Process

The Vendor/Contractor shall familiarise himself with the requirements of the alarm systems. Cabling
requirements will be as shown on the relevant drawings.

3.5.1 Control Room Alarm Systems

The Vendor/Contractor shall ensure that panel mounted annunciator units which are being installed are
solidly clamped or fixed to the panel. The units shall be earthed direct to the panel framework by means of
a separate 7.9 k.c.mil (4.0 mm²) single core stranded copper earth cable with a green/yellow or green PVC
sheath. Fixing clamps must not be relied upon to provide the necessary earth path between the unit and the
panel.

Individual initiating contacts shall be wired into the annunciator via disconnecting links, (Klippon type
SAK R or equal) to afford rapid disconnection facilities for testing. The box or trunking containing links
shall be located at the rear of the instruments panel in a position where it is readily accessible when the
instrument panel is fully piped and wired. All incoming cabling ends shall be ferruled (see Section 3.7.4.8)
with the number of the associated initiating device.

Before "Megger" (Insulation Resistance) testing the cabling it shall be disconnected from all equipment to
avoid damaging the latter.

For remote (i.e. on plant) initiation switches, all cables shall enter from below, to prevent the ingress of
water through the gland entry.

3.5.2 Local (Adjacent to Process Equipment) Alarm Systems

Local annunciators will normally be mounted on the control panel associated with a particular item of
process equipment or else housed in individual cubicles, designed and intended to enhance their
weatherproofing.

All the stipulations above for control room alarm systems, apply. In addition, because of the usually
exposed nature of the position of these units, the Vendor/Contractor shall replace all covers and enclosures
immediately after work, and shall arrange for suitable additional temporary protection during the
construction phase prior to commissioning, where necessary.

3.6 Accidents

Prior to commencing work on site, the Vendor/Contractor shall familiarise himself (by consultation with
the Owner) of the procedure, documentation and notification required following an accident or dangerous
occurrence involving his personnel, for the particular site on which he is working.

3.7 Cables

This section covers good practice for both LV & MV cables. In the case of MV cables, a maximum Uo/U
voltage of 8.6 kV/15 kV is assumed, since for higher values special consideration is required and shall be
agreed at the contract stage with the Vendor/Contractor or the Owner, as applicable.

3.7.1 Cable Types

The types of cable to be used will be as stated in GES L.02 and detailed on the drawings and may be varied
only with the permission of the Vendor/Contractor or the Owner, as applicable.

IEC cable CSAs are always in metric dimensions (mm²). American conductor sizes are often American
Wire Gauge (AWG) for the smaller sizes and circular mils (c.mil) for larger sizes. However, because
circular mil is a term universally used in the U.S.A. and based on the mil (one thousandth of an inch) this
specification refers solely to C.mil and not to AWG.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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3.7.2 Cable Routes and “Pulling In”

Cable routes and groupings indicated on the layout drawings shall be adhered to.

Where particular cable routes and cable grouping are indicated or specified on approved drawings, they
shall be adhered to. Failure to meet this requirement will result in the Vendor/Contractor having to correct
the installation at his own expense, and without detriment to any anticipated target completion date.

Where routing is left to the Vendor/Contractor’s discretion and cable runs, particularly cable tray runs, are
being established or installed, the Vendor/Contractor shall determine by inspection, and liaison with the
Owner, the requirement for the instrument cable runs in the area under review. Where practicable, common
cable routes shall be established, thus reducing the amount of duplicated installation work.

All cables shall be left clear of all process and service pipes. There shall be a minimum distance of 16
inches (400 mm) between any cable and the lagging of steam or hot process lines.

Cables shall not be supported from or attached to pipes, either directly, or on top of lagging unless shown
on the certified drawing.

Every effort shall be made to keep all cable runs in reasonably accessible positions. Cables shall, as far as
possible, be run in groups, and not independently, however, MV Power Cables shall be kept at least 10
inches (250 mm) from LV power cables in a horizontal or vertical plane as is relevant.

Instrument cables shall be at least 3 ft (1 m) away from Medium Voltage (MV) Electrical Power Cables.

The minimum height of cables or cable supports crossing structure walkways or other minor access ways
shall be 7 feet (2100 mm) - measured to the underside.

Where cables pass from one level to another, they shall be run vertically and not inclined unless specified
on drawings.

Where cables pass vertically through floors, platforms, walkways etc., protection against mechanical
damage shall be provided to a height of 10 inches (250 mm) above the floor level, by substantial,
permanently fixed metalwork or PVC ducts. Such protective metal work shall include reasonable space for
the installation of additional cables. The Vendor/Contractor shall consult the Owner as to the precise form
of steelwork required. Where cables pass through solid floors access holes must be sealed by means of
cable transits to inhibit the spread of fire and any deviation shall be approved by the Owner.

Power cables shall be run separately from cables used for intrinsically safe circuits, instrument
thermocouples and electronic signals.

The bending radius of any cables shall be not less than the minimum values specified by the manufacturer.

Cables shall be run in smooth parallel formations. Twists, crossings or inter-twining of cables is not
acceptable.

The Vendor/Contractor is required to keep a record of all cable lengths pulled for submission to the Owner.
The Vendor/Contractor is required to produce cable pulling schedules to be updated as drums of cable are
used and to advise of potential shortfalls as soon as identified. A regular (daily/weekly) report shall be
submitted to the Owner.

All conduits, shall be suitably temporarily sealed immediately on installation to prevent entry of dirt and
water. The conduits shall also be permanently resealed following the installation of the cables.

Upon installation, cables shall be temporarily marked for identification purposes, pending termination and
the fitting of permanent identification markers.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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Where cable ends are coiled pending installation, or awaiting clearance of an area by other trades, the
cables shall be coiled individually, not in multiple numbers. The coils shall be as large as is practicable and
the coils of each twine, to avoid tangling. Binding or armouring wire shall not be used for this purpose.

The installation (including any bending or straightening) of Thermoplastic (PVC), Elastomeric (XLPE) or
paper insulated cables shall not be carried out when the ambient temperature is at or below 0°C (32°F)
because of the danger of damaging the insulation or sheath. The use of heated "elephant" tents or shelters,
over such cables, or coils of cable and/or the application of direct heat to the ends of the conductors of such
cables, is to be employed only with the knowledge and prior consent of the Owner. Any tents or shelters
used for this purpose shall be fireproof.

Joints in cable runs shall be used only on the instructions of the Owner. Any joints in polyvinyl chloride
(PVC) or crosslinked polyethylene (XLPE) cables shall be of the "Scotchcast" (or equal) type and shall be
located on the relevant layout drawings.

3.7.3 Cable Terminations

All cable ends shall be properly terminated in glands of the correct size and type. Tapped entries are the
preferred method. Normally apparatus will be supplied with, or suitable for, tapped entries but occasionally
equipment having clearance entries may be provided. Glands will not generally be supplied with the
apparatus.

Outdoors, cable entries wherever possible shall be located on the underside of apparatus, in order to avoid
the entry of water or other liquids via the cable. Where bottom entry is impracticable, side entry may be
used provided the cables leave with a downward slope.

All cables shall be so supported that no strain is placed upon the cable gland or equipment.

Where the thickness of a screwed gland plate is less than the axial length of the thread free portion plus 3
full threads of the gland required, an inner "Star" washer and locknut shall be installed. In the case of
equipment where clearance holes are provided for the glands, an inner "Star" washer and locknut shall be
installed. Clearance holes shall be no larger than necessary, and shall be cleaned up to remove any drilling
rag and sealing washers shall be filled for outdoor installation.

Star washers shall be correctly sized and locknuts shall be of the hexagon shaped type unless space
precludes the use of anything other than the ring type of locknut.

Cable entry holes in flameproof equipment, shall not be drilled out or altered in any way.

All surplus cable entries in apparatus shall be sealed by use of the appropriate type of screwed plug (eg
explosion-proof type plugs in explosion-proof equipment).

All stopper plugs used in explosion-proof apparatus shall be of the type requiring an "Hexagonal" or other
special key.

All stopper plugs used in non-explosion-proof apparatus shall be of the hexagon headed type, which
effectively prevents the plug being screwed right into the terminal chamber.

All apparatus supplied with stopper plugs shall be checked to ensure that the correct type of plugs are
fitted.

Additionally, the Vendor/Contractor’s personnel may be required to demonstrate their ability to install
correctly any type of cable gland in use to the satisfaction of the Vendor/Contractor or the Owner or his
representative.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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At the Owner's request, the Vendor/Contractor shall be prepared to replace at his expense badly installed
severely marked or damaged glands or locknuts.

Where glands are situated outdoors, they shall be effectively sealed against the ingress of moisture by the
use of self amalgamating PVC tape or by smearing with Denso (or equal) paste, and the fitting of either a
PVC shroud, or the application of a layer of Denso (or equal) tape. The choice of method varies from
works to works and will be specified for each contract. For glands located in oxygen rich atmospheres see
Section 3.36.

Shrouds shall be correctly sized and fitted. Where shrouds are not used and tape is used instead, sufficient
is to be applied to continue the moisture seal back along the cable sheath.

Glands located indoors shall not be fitted with shrouds or otherwise weatherproofed unless specifically
indicated as such on the installation drawings.

Explosion-proof type glands shall be used with all explosion-proof apparatus, irrespective of the
classification of the area in which it is installed. These shall be sealed if required by the regulations.

Glands with an internal seal shall be used with Zone 2 lighting fittings and a Dowty bonded seal type PP45
(or equal) shall be fitted between the gland and the apparatus.

The Vendor/Contractor shall ensure that all his personnel are familiar with the various types of glands to be
used both as to appearance and method of installation.

3.7.4 Cable Trenches and Ducts

General:

Cables shall not be installed in trenches or in underground ducts (conduits) unless called for on the
drawings. Where a trench or duct passes from a hazardous to a safe area, it shall be sealed in a manner and
in a location either shown on the drawings or decided by the Owner.

Sand and earth are not suitable sealing materials. Unless specific instructions are given by the Owner each
cable in a trench or duct shall be a complete length from termination to termination. In the event of such
instructions being given, the position of joints shall be marked to the requirements of the Owners.

- The Vendor/Contractor shall ensure that all MV cables, LV cables and control/instrumentation
cables maintain proper segregation distances throughout the installation.

- All signal/instrument cables shall be installed at a distance of 1 foot (300 mm) from power cables,
operating below 1,000 volts and 40 inches (1,000 mm) from Medium Voltage (MV) cables.

- The depth of the cable trench shall be as indicated in Contract Drawings. Signal/instrument cables
and power cables operating below 1,000 volts shall be a minimum of 2 feet (600 mm) below
grade. Cables operating at Medium Voltage (MV) shall be a minimum of 3 feet (900 mm) below
grade.

- The cable trench formation shall be trimmed and shall be free from all extraneous materials that
may cause damage to the cables.

- Granular bedding for cables shall be constructed by spreading and compacting sand to 2 inches
(50 mm) minimum depth over the full width of the trench.

- Backfilling shall consist of sand being placed and compacted over the full width of the cable
trench to a minimum of 6 inches (150 mm) above the largest cable. Thereafter, a cable tile shall
be laid. A yellow plastic warning tape shall be placed 1 foot (300 mm) below grade, above the
tile.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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- Trenches shall not be backfilled until all cables have been inspected, tested, and approved by the
Owner.

3.7.4.1 Cable Trenches in Open Ground or Pebbled Areas

The responsibility for the excavation and back filling of cable trenches lies with the Vendor/Contractor.
Before commencing any excavations the Vendor/Contractor shall determine by liaison with the Owner
what the finished grade level will be along the line of the proposed route and also if clearance or permit to
work certificates are necessary.

Prior to laying any cables in the trench, the bottom shall be levelled, reasonably compacted and generously
spread with about 2 inches (50 mm) depth of clean sand. Cables shall be laid in the trench in strict
accordance with the design drawings, paying particular attention to the depth of laying and the designated
spacings between cables and cable groups, to prevent undue heating of the cables. If two layers of cables
are to be installed then about 2 inches (50 mm) depth of clean sand shall be placed over the first layer, prior
to laying the second layer.

As each layer of cables is laid in place, and before covering in sand, each cable shall be given a visual
inspection and an insulation test, in the presence of the Owner. A final layer of clean sand shall be placed
on the top layer of cables, followed by a row of correct width, interlocking, suitably marked cable tiles.
The tiles shall cover the width of the cable run, with a reasonable margin of overlap at each side.

Prior to backfilling, the Vendor/Contractor shall consult the Owner, to determine whether any additional
spare cables are to be installed in the trench, and also the location and type of termination required, for
these cables. The trench shall then be backfilled.

A continuous line of proprietary plastic marker tape, (see Section 3.7.4.6) shall be installed along the line of
the cable, 12 inches (300 mm) below the surface, to give future excavators pre-warning of buried cables.
After backfilling, the trench shall be left to settle, the route markers referred to in Section 3.7.4.6 being
installed on a temporary basis to give immediate warning to other trades of the presence of buried cables.
These shall be finally and permanently positioned after the trench excavations have substantially re-settled
and have been re-levelled.

The Vendor/Contractor shall be responsible for adequate liaison with the Owner and with other trades in
determining the detailed location of cable trenches, and in minimising interference with other underground
equipment and cables.

3.7.4.2 Cable Trenches in Paved (i.e. Concreted) Areas

The procedure and precautions for cable laying, inspection and testing laid down in Section 3.7.4.1 shall be
followed except that the continuous marker tape is not required.

The trench shall be finally filled with clean dry sand, the sand being tamped down to minimise further
settlement. The trench will be finished in accordance with the design drawings with 2 inch (50 mm) layer
of weak mix cement, coloured orange, and floated level with the surrounding paved area, or, with pre-cast
covers, marked "Electric cables". This final covering will be installed by the Vendor/Contractor. Constant
attendance during the whole of the operation to watch for possible actions which might damage the cables
shall be provided by the Vendor/Contractor.

3.7.4.3 Cable Trenches in Substation or Control Room Buildings

The cable trenches will be provided by the Vendor/Contractor in accordance with the approved drawings.
The spacing and support of cables shall be as detailed on the design drawings. The trenches shall be
unfilled and provided with covers as specified on the drawings.

3.7.4.4 Cables in Underground Ducts (conduits)

 GENERAL ENGINEERING SPECIFICATION GES C.06
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Cables in ducts shall be installed in the order and location shown on the design drawings. Cable markers,
as described in Section 3.7.4.6 shall be fitted on each cable, just before it enters the duct and immediately
after it leaves.

Draw-in socks/pulling grips shall be used on all large cables, and a recognised cable lubricant (eg a mixture
of plumbago and soap solution) shall be used if difficulty is experienced with the installation. Duct ends
shall be smooth and ‘snag’ free and the ducts shall be drawn through to remove debris before commencing
to install cables. Where small ducts are provided to convey cables from the foot of structural steelwork to
adjacent apparatus, such ducts shall be left with an upstand of 10 inches (250 mm) above the floor level.
These ducts shall be temporarily plugged, prior to being cast in the flooring, pending installation of the
cable. Following installation of the associated cabling, both ends of each duct shall be stemmed, with
wooden plugs, and then wrapped with Denso (or equal) tape to prevent ingress into the duct of solid
materials, water or process liquids.

Note:

Duct and pipe crossings shall extend at least 1 foot (300 mm) beyond the limits of the area requiring ducts;
draw wires shall be installed in each duct.

3.7.4.5 Cable Protection

Cables buried in open ground or pebbled areas shall be protected by cable tiles, as detailed in Section
3.7.4.1.

Cables rising vertically through floor levels, shall be protected by steelwork as detailed in Section 3.7.2.

Where the route is left to the Vendor/Contractor’s discretion, it shall be chosen to minimise the likelihood
of damage from other trades, and as a result of possible future removal of major items of plant equipment.
(See Section 3.13 - re “as built” drawings).

Where fireproofing is to be applied to cable runs, it will be arranged by the Vendor/Contractor.

The Vendor/Contractor shall acquaint himself with the final intended arrangement and ensure that he does
not impede the later installation of the fireproofing.

3.7.4.6 Cable Markers Individual and Route

Individual cables shall be marked at each end with their respective numbers, as stated in the cable schedule.
Markers shall be Critchley type ‘S’ (or equal) firmly fixed to the cable and orientated, so that the markers
are clearly visible from the direction in which the cables would normally be inspected. For lighting
circuits, the feeder cable up to the first fitting shall be marked. Cables between fittings shall not be marked.

If intermediate cable markers are required, on cable runs, this will be stated in detail on the design
drawings. Where intermediate markers occur at the same point on a multi cable run, they shall be staggered
over a distance of 3 feet (1,000 mm) to aid identification and prevent markers on adjacent cables chafing
each other.

All markers shall be installed on a continuous basis, as the cables are terminated i.e. the markers shall not
be installed altogether, at a late stage in the job.

Concrete cable route markers shall be installed 1 foot (300 mm) above grade along the line of all
underground cables in unpaved areas and shall be located not more than 33 yards (30m) apart and at every
change of direction along the longer buried cable routes, such that they indicate quite clearly the line of the
buried cables.

In addition, marker boards of similar size and type shall be used to indicate the location of any buried
 GENERAL ENGINEERING SPECIFICATION GES C.06
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joints. The boards shall be marked ‘Joint’ Cable No......... From......... To........... in red letters on a white
background.

A continuous line of proprietary heavy duty coloured plastic marker strip marked ‘Danger Electric Cables’
(in English & Arabic) shall be placed along the line of all buried cables, 1 foot (300 mm) below the surface,
to give future excavators advance warning of likely danger.

All underground cables shall be marked at all joints, take-off points and other strategic points with heavy
duty embossed lead markers, showing the cable number, wired onto the cable.

3.7.4.7 Cable Supports and Fixings

Supports and racks for main cable runs will generally be provided and erected complete by the
Vendor/Contractor, ready for the installation of cables.

On pipe bridges and structures where cable accommodation is not already provided, hangers fabricated
from M.S. angle and spaced at 2.5 feet (750 mm) centres or the use of an approved proprietary cable rack,
as appropriate according to the number of cables in the run, shall be installed. Fixings to structural
steelwork shall preferably be by means of clamps of the ‘Lindapter’ (or equal) type. Welding to vessels or
tanks, due to the possibility of their being stress relieved, is not permitted without the permission of the
Owner. Welding to structural steelwork is normally acceptable but the Vendor/Contractor shall consult the
Owner before commencing any welding work. Before commencing welding work the Vendor/Contractor
shall discuss with the Owner the requirements regarding fire permits, safety precautions (including
earthing) and skill test approval for welders.

Steelwork shall not be drilled without the permission of the Owner unless the drilling is called for on an
approved Drawing.

The use of explosive powder actuated tools will not normally be permitted, particularly so in areas open to
other trades or personnel. This restriction may be relaxed at the discretion of the Owner, who may permit
the use of such devices in certain specified areas, at certain defined times.

In the event of any such permission being obtained the Vendor/Contractor shall ensure that personnel
handling these tools are adequately trained and fully aware of the dangers of misuse. Cartridges shall be
stored in accordance with the Owner's recommendations and the issue and return of cartridges strictly
controlled and recorded.

All nuts and bolts shall have metric threads.

All metalwork supplied by the Vendor/Contractor shall be suitably treated, before and after erection, as
detailed in Section 3.40.

Where sections of the structure are clad, or are to be clad in fireproofing material, basic supports for cables
or fittings will be welded to the structure before the fireproofing material is applied. However, if the
Vendor/Contractor or the Owner can foresee the need for additional supports on sections of steelwork
which is to be fireproofed, the Vendor/Contractor shall make arrangements with the Owner for this work to
be effected.

Small numbers of cables may be clipped direct to the surface of the structural steelwork fire-proofing using
rawlplugs, toggle bolts, “redhead” bolts or the like.

This method of running cables must be discontinued if the fireproofing cracks or spalls. Banding clips
which pass right round the fireproofed member are not forbidden entirely, but their use must be minimised.

Where cable tray is used, whether inside a building, or outside, it shall be of the heavy gauge return flange
hot dipped galvanised type. PVC coated tray shall not be used unless specified. Where junctions are
formed in tray they shall be secured by four 6 mm galvanised roofing bolts. Where cable tray is fixed flat
against a vertical surface, (ie all cable tray in the same plane) the use of proprietary sweep bends and
 GENERAL ENGINEERING SPECIFICATION GES C.06
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junctions is preferred. Proprietary bends must be used when vertical tray changes to horizontal.

Proprietary fittings should always be used. Tray may be cut and formed provided that the methods used
meet the approval of the Owner.

Cable tray shall not be used where the final content of a cable run, allowing for possible additions, is
expected to be less than two cables. Such small runs shall be clipped direct to the surface.

The distance between supporting brackets for cable tray shall be less than 10 feet (3 metres) and such
supports shall be made so as to allow reasonable hand access behind for clip fixing purposes so far as is
possible.

Any holes cut in cable tray for cable access shall be lead lined or lined with PVC (or similar) material to
prevent chafing of the cable sheath.

On major overhead horizontal cable runs (e.g. on hangers or “ladders”) no clipping or fastening of cables is
required, though they may be banded together for the sake of appearance using Beta strip, or the equivalent.

No clipping or fastening of cables is required on overground routes, whether of the rack, or “tree” type,
unless specified.

The Vendor/Contractor shall ensure that particular care is taken when lead covered cables are run on such
racks or trees. The amount of sag required between cable supports, to ensure satisfactory long term
operation of the cables will be shown on the certified installation drawings.

On vertical runs, cables shall be clipped at intervals as shown in ‘Table 1’ overleaf. Similarly on small
horizontal runs, and on all tray plate, cables shall be clipped at the same intervals and at each side of every
bend or change in direction.

All cable racks and cable trays shall be bonded to earth ensuring earth continuity is maintained from both
an electrical and static electric point of view.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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Table 1 - Spacing of Supports for Cables

Spacing of Clips

Overall Non Armoured Rubber, Armoured Cables Mineral-Insulated

Diameter of P.V.C. or Lead Sheathed Copper Sheathed
Cable Cables Cables
Horizontal Vertical Horizontal Vertical Horizontal Vertical
1 2 3 4 5 6 7
mm* mm* mm* mm* mm* mm* mm*
Not exceeding 9 250 400 - - 600 800
Exceeding 9 & 300 400 350 450 900 1200
not exceeding 15
Exceeding 15 & 350 450 400 550 1500 2000
not exceeding 20
Exceeding 20 & 400 550 450 600 - -
not exceeding 40

* For the conversion of mm to inches, divide the Table 1 figures by 25.4.

Where clipping or fastening of cables (other than MICS) is required ‘Insuloid’ type SAS cable binders, or
similar, shall be used. This is mandatory for switchrooms and Substations and is preferred for all other
situations where conditions allow them to be used, on account of their ability to cater for additional cables.

When cables are run on tray in a multi cable run, they shall be dressed together and secured with a common
fastening.

The use of wire binders for temporary fixing of cables in any part of the plant is prohibited because of the
danger of them inadvertently entering apparatus. For such temporary fixings plastic string or thongs shall
be used.

Where cables of 69 k.c.mil (35 mm²) or above are to be run vertically or on other than major horizontal
routes, individual BICC claw type cable cleats, (or equal) shall be used to secure them.

No acid resistant or other type of tiled surface shall be cut into or drilled for any fixing unless shown as
such on an approved drawing, or authorised by the Owner (any cutting or chasing of such surfaces will
normally be carried out by other trades).

3.7.4.8 Cable Conductor Connections

XLPE and PVC insulated cables shall be terminated with proprietary compression type lugs, unless the
equipment being connected to is equipped with shrouded connectors of the sleeve, or ‘Klippon’ type. The
make of lug required for the whole of any particular installation will be specified by the Owner. Klippon
type SAK.10 connectors (or similar) which have a curved pressure plate shall not be used. The Klippon
type SAK.6 (or equal) shall be used; this accepts similar sizes of conductors, and has a flat pressure plate.
“Scruitt” type connectors shall not be used.

Conductors shall be properly entered into the lug as indicated by the inspection hole in the neck of the lug,
and the Vendor/Contractor shall pay particular attention to ensure that personnel entrusted with this work
are conversant with the required techniques, and fully aware of the standard of workmanship required.

Cable cores for power equipment (e.g. MCCs, motors, process heaters etc) shall be set into the correct
positions for strain free connections before crimping on the terminating cable lugs. A surplus lug may be
slipped uncrimped over the free ends to afford additional purchase to assist in setting the cables, but
immediately afterwards this lug shall be hammered flat, or otherwise disposed of in such a manner that it
 GENERAL ENGINEERING SPECIFICATION GES C.06
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cannot inadvertently be used to make off any permanent connection.

After crimping on new lugs to form the permanent terminations these lugs must not be used to assist in any
further setting of the cables. All terminations shall be strain free.

Soldered lugs shall not be used for either copper or aluminium cored cables unless specified on an
approved drawing (e.g. single core incoming cable terminations into a motor control centre) or approved by
the Owner. (N.B. soldering is normally kept to an absolute minimum on the Petrochemical type of plant,
because of later difficulties in obtaining ‘hot work permits’ if further work is required, once the plant is
running).

Where ferruling is required e.g. trip and alarm initiating cabling, it will be specified on the approved
drawings. Where required all ferrules shall be of Critchley (or equal) manufacture of the thread-on type.
Ferruling shall be strictly in accordance with the relevant schematic drawings and ferrules shall be threaded
on the tails in such a manner that they all read the same way, from the terminal strip outwards. Ferrules
shall be orientated for easy inspection from the normal viewing angle.

(Where ends need to be double ferruled because of the transposition from one equipment
Vendor/Contractor's numbers to another, the two sets of numbers shall be of different colours).

3.7.5 Mineral Insulated Copper Sheathed Cables (MICS)

Copper/PVC sheathed cable only shall be used.

MICS cable shall not be used in situations where there is likely to be vibration (such situations will be
identified by the Vendor/Contractor or the Owner).

The use of MICS cable for switchgear interconnections, inductive load cabling or d.c. is prohibited.

The sheath return concentric wiring system shall not be used.

For trace heating installations see Section 3.42.8.

MICS cable shall be 600 V grade and ¾" ET (20 mm) cable glands shall be used as far as possible.

The bending radius of any cable shall be not less than that recommended by the manufacturer.

Copper clips with brass nuts and bolts shall be used for fixing the cable. The spacing of clips shall be as
given in ‘Table 1’ in Section 3.7.4.7.

Upon completion of each length of MICS cable, the ends must be sealed immediately preventing the
ingress of moisture.

For MICS cables a tight loop of cable not less that the minimum bending radius laid down in BS 7671 (the
IEE Regulations) or NEC shall be made before terminating cables in push buttons, small motors,
instrument switches and the like, in the plant area to leave sufficient slack for a further cable make off if
required at some future date.

Before any installation commences all MICS cables shall be tested for insulation and continuity, ensuring
damp creepage has not occurred at the ends.

3.8 Compressed Air

Where plant service compressed air is on the construction site, it may be available to the Vendor/Contractor
for his use. The Vendor/Contractor shall obtain permission from the Owner to use this normally free of
charge for operating portable tools etc. He must not, however, disconnect other equipment already
 GENERAL ENGINEERING SPECIFICATION GES C.06
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connected to an outlet he wishes to use nor connect tools to any instrument air header or instrument point
without permission.

The Vendor/Contractor shall ensure that all his personnel know how to handle compressed air supplies.

The correct type of hoses shall be used with portable tools. The use of non-armoured, thin wall PVC
tubing is forbidden.

3.9 Conduit Installations

3.9.1 Conduit Installations in Hazardous Areas

Conduit installations are not permitted in hazardous areas unless specifically called for on approved
drawings in which case full instructions regarding accessories, compound filling of chambers etc. will be
given.

3.9.2 Conduit Installations in Safe Areas

Conduit shall not be used in outdoor situations unless specifically called for on approved drawings or by
the Owner, in which case full instructions regarding weatherproofing etc., will be given.

Conduit installations in buildings or other enclosures shall be in accordance with the standards in use for
the installation and in addition the following shall apply.

Metal conduit shall be rigid hot dipped galvanised steel. All conduit boxes shall be made of malleable iron,
with cast iron covers fixed by greased screws. Larger type sheet metal boxes may be used for specific
purposes, at the discretion of the Owner.

Corners shall be turned by means of hand made bends of radius not less than that given in Table No. 3 of
BS4568 or where this is impracticable by means of malleable iron conduit boxes. All conduits shall be
bent cold.

All conduits buried in concrete, cement, or plaster, or erected in roof spaces, or ducts, or similar situations
shall be galvanised.

Conduits shall not be installed where condensation is likely to be encountered.

Fittings used in conjunction with galvanised conduits shall be galvanised, or equally well protected from
corrosion.

Black enamelled conduits shall only be used when specified on approved drawings. In most cases the use
of PVC conduit will replace black enamelled conduit which would be restricted to surface work in
thoroughly dry and well ventilated situations.

Conduits, conduit fittings and all metal enclosed apparatus shall be mechanically continuous so as to form a
protective enclosure for cables throughout.

In every conduit system an earth continuity conductor consisting of a stranded green or green/yellow PVC
insulated copper conductor of appropriate size for the associated main cables, shall be installed. In
addition, earth continuity shall be further assured by the use of spouted boxes or smooth bore brass bushes
and couplers.

All threaded joints shall be given a liberal application of white lead, before they are made up and shall be
screwed up tightly with as little thread showing as possible. Any exposed threads shall be cleaned and
painted immediately after the erection of the conduit installation to prevent rusting. (The exposed threads
of galvanised conduits shall be painted with a suitable proprietary cold galvanising paint).
 GENERAL ENGINEERING SPECIFICATION GES C.06
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Conduit connections to trunking systems shall incorporate ‘Star’ washers and smooth bore brass male
bushes.

Conduit shall be clean and smooth both inside and outside. Both ends of every length of tubing shall be
freed from any burrs or sharp edges by filing or reaming before being erected.

The use of running conduit joints or couplers shall be kept to a minimum.

In conduit runs containing cables of size up to and including 7.9 k.c.mil (4 mm²), a standard draw in box or
inspection fitting shall be included every 11 yards (10m).

No more than two 90° bends shall be included between any two draw in points.

Side entry conduit boxes to which lighting fittings are attached shall be securely fixed irrespective of the
support from the conduit.

All conduits and boxes and accessories comprising one circuit, or portion of the installation, shall be
erected before any wires on that circuit are drawn in. Conduit shall not be dismantled to ease the
installation of cables. Conduits shall be “swabbed” through before any cables are drawn in. Ends of conduit
left open during any building operations shall be effectively plugged and any exposed threads shall be
temporarily protected with PVC adhesive tape.

Surface conduits shall be fixed to building fabric by means of cast iron distance saddles to give not less
than 0.25 inches (6 mm) clearance between the conduit and the walls. Saddles shall be fixed at even
spacings of not more than 1.1 yards (1 m) and so arranged that the distance between any conduit box or
bend and the adjacent saddles does not exceed 9 inches (225 mm).

Where a surface conduit run turns through a wall, a back outlet box shall be provided.

In buildings, conduits shall be concealed where possible by laying in the screeds of floors, chases in walls,
in ceiling voids or in service ducts and shall be securely fixed in position with straps or saddles. Conduits
and conduit boxes laid in concrete poured “in situ” shall be fastened to the reinforcement before concreting.
Extension rings shall be fitted to sunk conduit boxes to which lighting fittings or pull switches are to be
attached if the distance between the box and the finished surface is more than 0.2 inches (5 mm).

Break joint rings of approved colour shall be provided for all suspended fittings where the gallery or ceiling
rose or ceiling plate does not exceed the diameter of the mounting box by more than 0.4 inches (10 mm).

Boxes for lighting switches shall be located 4.5 feet (1350 mm) above floor level and 0.5 inches (12 mm)
from any door architrave. Allowable 'conduit fill' shall be in accordance with the regulations utilised for
the installation.

Where several switches which are connected to the same phase of the supply are shown at one point on the
drawing a ganged box shall be used. Where several switches which are connected to different phases are
shown on the drawing at one point, multi switch boxes in which each phase is segregated in a separate
compartment covered by a separate internal warning plate, shall be used.

The preferred method of connecting apparatus which may be subjected to vibration is by means of flexible
armoured cable but if this method is impracticable proprietary flexible conduits may be used with the
approval of the Owner. The ends of the flexible conduit shall be connected to the fixed conduit system and
the equipment by means of approved adaptors fitted with an external lug for earthing purposes. The
adaptors shall be of rust proofed malleable iron.

An external, stranded conductor, green/yellow insulated single core shall be neatly lapped round the length
of flexible conduit and connected to the earth lugs of the flexible conduit adaptors.

Where overhead conduits span between adjacent structures, installations shall be made to allow freedom of
 GENERAL ENGINEERING SPECIFICATION GES C.06
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movement of structures due to expansions, or wind. This may be accomplished by putting a 90° bend at
one or both ends of the span, and placing conduit clamps 30 inches (750 mm) behind the bend.

All conduit fitting connections, shall have at least five full threads engaged.

Where several cables are drawn into a common conduit, all cables shall be pulled in simultaneously. The
cables are to be “combed” before pulling in and care shall be taken to avoid kinks and twists occurring
during the pulling in.

Only french chalk or manufactured pulling compounds may be used as a lubricant to assist drawing in of
cables.

All cables installed in conduit shall be of the stranded copper PVC or XLPE insulated type.

The number of cables drawn into any conduit shall not exceed that specified in the latest edition of the
standards in use for the installation.

Cables from separate distribution boards shall be run in separate conduits. All cables shall be in one
continuous length from termination to termination.

Non-metallic conduit systems shall not be installed unless called for on an approved drawing.

Properly rated and fixed connector blocks shall be used for all connections. The use of Scruitts or similar
type connectors in junction boxes is not permitted.

All phases and phase and neutral return for any supply shall be run together in the same conduit.

3.10 Communication and Fire Alarm Systems

The locations of the basic hardware, e.g. speakers, call points, and communication amplifier equipment will
be shown on approved drawing. This equipment will normally be mounted by the Vendor/Contractor, and
commissioned at a later date by the equipment maker’s representative.

All items shall be firmly and substantially fixed in the positions shown on approved drawings unless these
positions are varied by specific instructions from the Owner.

Acoustic booths which are particularly susceptible to damage, shall not be installed in any plant area until
most, or preferably all, of the piping has been erected. Care shall be taken to mount this type of booth
firmly, and apparatus contained within it must be bolted right through the acoustic section material.
Driving fixing screws for apparatus into the acoustic material is not acceptable.

Where the Vendor/Contractor is not responsible for connecting up items of equipment but is only to run
and terminate the interconnecting cables, identifiable tails of generous length shall be left to facilitate the
completion of the connections.

Goggles and protective clothing shall be worn to prevent gas or gas and liquid discharge from cells from
affecting the eyes and body when any work is carried out on cubicles which contain batteries (usually of
the nickel-iron or nickel-cadmium type), particularly when initially removing stoppers fitted for the sole
purpose of transportation.

Where associated transmission aerials are mounted on poles, or masts, the Vendor/Contractor shall check
that the supports are sufficiently rigid, and that the mast is easily dismountable to enable the maker’s
representative to test aerial connections and polarity and facilitates future maintenance access requirements.

All equipment located in a substation or control building shall be adequately and firmly fastened down.
Desk mounted handsets, call sets or speakers, shall be firmly fixed to the desk, either by screws through the
 GENERAL ENGINEERING SPECIFICATION GES C.06
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desk into the feet or some equally satisfactory method, in a position to be agreed by liaison with responsible
process personnel on site. These items shall not be left loose, on a desk top, because of the risk of damage
by being knocked to the floor.

3.11 Distribution Boards

Boards shall be mounted such that the top of the board is not more than 2.2 yds (2m) above floor level,
unless otherwise shown on approved drawings.

Distribution boards shall be fastened direct to brickwork indoors, and to structural steelwork or floor stands
outdoors, as shown on the approved drawings. Steel frameworks or supports shall not be provided for
boards indoors etc., unless these are called for on the drawings. Where boards are fixed to brickwork,
Rawlbolts or equal of an appropriate size shall be used. All fixings shall be into the brickwork, not the
bond between bricks unless this is not possible because of the fixing centres of the equipment, in which
case upper fixings shall be into the brickwork.

All boards shall have as many entries drilled and tapped for outgoing circuits as there are ways on the
board. Spare cable entries shall be fitted with appropriate stopper plugs maintaining any Hazardous Area
Certification that may be prevalent.

Individual cable cores shall be left reasonably long to enable the cable to be transferred to another way, if
necessary. Cable cores shall not be formed together into a loom.

Neutral connections shall be connected to the neutral bar in such a position as to be logically associated
with the fuse(s) of that circuit.

Single phase circuits shall not be taken from triple pole and neutral boards, due to the difficulty of
adequately isolating the neutral, unless shown on approved drawings.

Distribution boards shall be fitted with Moulded Case Circuit Breakers (MCCB) Miniature Circuit Breakers
(MCB) or fuses as shown on the drawings.

Individual distribution boards shall be fitted with devices at the maximum for which the board is rated, care
being taken to cater for discrimination with upstream devices, unless shown otherwise on approved
drawings. All devices in any one particular board shall be of the same rating, so that if several circuits are
isolated at the same time, devices cannot be incorrectly replaced. Fuses with special motor starting
characteristics shall not be used in distribution boards, unless shown on approved drawings.

All distribution boards shall be labelled. The main labels shall be of white traffolyte with black letters of a
suitable size.

For all industrial type boards, main labels shall be firmly fixed by the use of nuts and bolts or self tapping
screws. Individual way duties shall be clearly and legibly printed on the way commitment chart or strip,
supplied by the board Vendor/Contractor.

Since explosion-proof boards must not be drilled or interfered with any way, the main labels shall be neatly
fixed with good quality adhesive. Individual circuit labels for flameproof boards shall be of white traffolyte
with black lettering, fixed as for the main labels, on the outside of the equipment.

Some works may require additional “Dymotape” way labels, either inside or outside the boards and the
Owner will notify the Vendor/Contractor of this requirement. The Vendor/Contractor shall be responsible
for the provision of these labels, when required.

3.12 Domestic Type Installations

This clause covers the type of domestic installation normally associated with control room, switchrooms,
 GENERAL ENGINEERING SPECIFICATION GES C.06
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plant offices etc; it does not cover installations in major buildings for which a particular contract
specification would be prepared. References shall be made to other clauses in this subsection viz Conduit
Installations (Section 3.9); Trunking (Section 3.42.7); Testing (Section 5.2).

The routes of cables and the appropriate positions of electrical apparatus such as lighting points, socket
outlets, switches etc will be shown on the approved drawings, but their precise position shall be determined
on site by the Vendor/Contractor. The Vendor/Contractor shall ensure that his work will not foul or
interfere with other services in any way.

The Vendor/Contractor shall inform the Owner of any chasing and cutting away of brickwork required for
installation of conduits. This work will be done by the Vendor/Contractor, together with ‘making good’ the
brickwork and plaster.

Where two or three core and earth, flat unarmoured PVC cables are terminated in a distribution board by
the use of clamping glands the earth wire of each cable shall be connected to an internal copper earth bar.
This earth bar shall be connected to the main earthing system by an adequately sized cable.

Thermostats controlling heating or ventilation systems shall be positioned such that they are exposed to the
correct atmosphere they are controlling (i.e. they must not be positioned in a draught, or a stream of hot
air).

All switches controlling such equipment shall be of the double pole type having a neon lamp, illuminated,
when the switch is ON.

All switches, and sockets, but not lighting fittings, shall be labelled, to show the feeder circuit reference.

3.13 Drawings

An adequate number of drawings will be issued by the Owner to the Vendor/Contractor prior to his
commencing work on site, and so far as is possible, these will be "Approved for Construction". Additional
drawings will be issued as necessary during the course of the job.

The Vendor/Contractor shall ensure that information marked on superseded drawings, is transferred to the
revised copies, before the superseded copies are destroyed.

Site layout and construction of the installations shall be carried out in accordance with the approved
drawings, standards, schedules, specifications and other documents which form an integral part of the
Contract, e.g.:

- Installation Block Diagrams;

- Installation and Layout Drawings;
- Earthing, Lighting, Heating, drawings;
- Cable and Equipment Schedules;
- Vendor/Contractor's Drawings and Installation Instructions;
- Electrical System Protective Relay Setting Schedules and Characteristic Curves, etc.

When the situation on site is such as to render any of the contract instructions inappropriate, e.g. where
advantage can be taken of a change in circumstance to the benefit of the work from any aspect, full details
should be brought to the notice of the Owner in order that appropriate action can be implemented.

From time to time “Preliminary” drawings may be issued and these will normally be followed by
“Approved for Construction” drawings in due course.

The Vendor/Contractor shall be in a position to demonstrate an acceptable Document Control system, for
 GENERAL ENGINEERING SPECIFICATION GES C.06
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receiving and dealing with drawings, immediately after commencing work on the site.

As-built drawings shall be returned as work progresses and at the completion of each section of work the
Vendor/Contractor shall return one signed and dated print of every drawing to the Owner. The prints shall
be marked up to shown the “as built” arrangement.

3.14 Distribution System (Owner's Site)

The Vendor/Contractor or his personnel shall not on any account operate, isolate, energise or interfere in
any way with the Owner's Distribution System. The entering of cables and connections to distribution
boards already energised shall only be carried out by the Vendor/Contractor’s personnel when working
under direct responsible Owner's supervision.

The Vendor/Contractor shall ensure that his personnel confine their attentions to the construction site in
question and do not enter or interfere with adjacent running plants.

3.15 Earth Continuity

Power system earth continuity will be maintained via the sheathing or armouring and glands of the cables
to items of equipment. Where additional earthing connections are required (e.g. in Zone 1 areas and for MV
equipment) these will be stated on the drawings. The Vendor/Contractor shall refer to Section 3.7.3 which
details the requirements for correct cable terminations and procedure and to Section 3.9, for earthing of
conduit systems, including the addition of a separate independent continuous earth core throughout the
conduit installation.

Instrument/Control Panels in control rooms or on the plant shall be bonded together across sections or
breaks by the use of 69 k.c.mil (35 mm²) single core copper, green/yellow PVC insulated cable, and a
connection of the same cross section shall be run to the nearest substation, or switchhouse earth bar.

All items of equipment (e.g. instruments, pushbuttons, switches, etc) located on such panels shall be
earthed either by an earth core or armouring in the supply cable or by a separate bond to the panels.

Earth continuity tests shall be carried out as directed by the Vendor/Contractor or the Owner.

3.16 Earthing for Substations

The earthing for substations, or switchhouses shall be installed as detailed on the approved drawings. Earth
link boards shall be installed approximately 24 inches (600 mm) above floor level and such that there is
ample space around them with adequate access for testing purposes.

Joints and tees between sections of copper strip shall be either thermit welded (“Cadweld”) or tinned and
rivetted or tinned and bolted. Each connection shall have a minimum of two rivets or bolts. Soldering only
is not permitted.

All cable taps and any joints shall be smoothed with a file to remove sharp edges.

Cable connections to copper strip shall be by a tinned lug crimped onto the cable and bolted to the copper
strip tinned in the local area. All earthing cable connections shall be PVC insulated coloured green/yellow.

The main earth bar shall be adequately supported from the brickwork by using earth bar clamps. No part of
the main earth bar shall consist of cable. There may be a requirement for the main earth bar to be painted
green. The Owner will advise the construction contractor, later in the construction stage if this is required.

All earth electrodes shall be driven at the positions marked, on the approved drawings, to the depth
indicated, although this may be increased if earth loop impedance tests are unsatisfactory.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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Their location shall be marked by proprietary earth pits and covers, which will normally be supplied as free
issue material.

Underground earthing cables shall be suitably protected against damage. They shall be buried 18 inches
(450 mm) below the finished ground level. Care shall be taken to determine the precise finished ground
level, irrespective of what level exists at the time of installation and the cables shall be buried accordingly
to the appropriate depth. Cables shall be terminated using the agreed type of compression lug.

Earth electrodes shall be tested as directed by the Owner.

Each unit forming part of any substation installation must be earthed by means of copper strip fastened to a
bolt or stud connection. This earth connection must be continuous and connected to all units and fastened to
the main earth.

All joints must be cleaned and treated as busbar joints. Special attention shall be paid to the earthing of
conduits, cable sheaths and cable glands (refer also to Sections 3.7.3, 3.9 and 3.15 of this specification).

For full earthing and bonding details, including MV/HV substations, reference shall be made to GES L.25.

3.17 Earthing For Protection Against Static Electricity

All earth electrodes shall be driven at the points shown on the approved drawings, and shall be tested for
earth resistance.

Bosses or lugs for tank and vessel earthing will normally be provided. Where these are not available the
Vendor/Contractor shall inform the Owner.

Bosses or lugs must not be “site welded” without the permission of the Owner since the stress relieving on
some vessels may be affected by local welding of this sort.

Where tanks are to be earthed in fully paved compounds, the earthing installation shall be as shown on the
approved drawing.

Reference shall be made to GES L.25.

3.18 Earthing Protection Against Lightning

The installation shall be carried out in accordance with BS 6651 (Code of Practice for protection of
structures against lightning), or NFPA 780 Lightning Protection Systems, and API recommended practice
RP2003.

Normally the protection against static electricity, referred to in Section 3.17 above, will also serve as
protection against lightning strikes for vessels, tanks, structures etc.

In the case of tall stacks, vessels, or in the case of buildings or office blocks, the design indicated on the
approved drawings shall be strictly adhered to.

Earth rods shall be tested for earth resistance, as directed by the Vendor/Contractor or the Owner.

Reference shall be made to GES L.25.

3.19 Erection of Specialist Equipment by Others

Certain specialist items of equipment (such as LV, MCCs and MV switchboards) will often be erected by
the manufacturer's personnel.

The responsibility for erection of these items will be a contractual obligation and will be confirmed by the
 GENERAL ENGINEERING SPECIFICATION GES C.06
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Owner to the Vendor/Contractor before he commences work. The Vendor/Contractor shall afford the
equipment manufacturer's erection team reasonable facilities, regarding access and co-operation, to ensure
safe, speedy and correct erection of the equipment. The Vendor/Contractor may be requested to supply a
small amount of unskilled labour for a short period to assist in the normal work associated with the
preliminary stages of erection, i.e. offloading and positioning.

3.20 Erection of Miscellaneous Equipment

The Vendor/Contractor will be responsible for the erection of numerous items of free issue miscellaneous
equipment, such as relay units, starter boards etc. All this equipment shall be firmly fixed and mounted in
the locations shown on the approved drawing.

Motor control centres, which are to be erected by the Vendor/Contractor in accordance with the instructions
supplied with the equipment. No strain at all shall be placed on the busbars, and on no account are these to
be loosely bolted together as an aid to lining up the board.

Generally speaking, all equipment shall be mounted in an accessible position with the general proviso that
the more likely an item is expected to require attention, the more accessible it should be. Substation and
switchhouse equipment shall not be mounted more than 2.2 yards (2m) above ground level unless this is
shown on an approved drawing or authorised by the Vendor/Contractor or the Owner.

During erection by the Vendor/Contractor, particular attention should be paid to the following:

- The substations/switchroom in which the switchgear/MCC is to be erected, should be as clean and

dry as possible and all debris should be cleared away

- Exclude dirt and debris from partially erected cubicles

- All openings that are not in immediate use should be blanked off or covered by clean sheets

- All electrical insulation should be kept clean and dry by being kept covered and, if necessary,
heated

Equipment doors shall be kept closed at all times unless someone is working on the interior. Loose
equipment, tools, fuses etc shall not be stored or left in cubicles under any circumstances.

3.21 Electricity Supplies to Contractor’s Huts

Supplies will normally be made available by the Owner. (For details see Section 3.42.6).

3.22 Electric Tools and Their Supplies

Electricity will be supplied on plant areas free of charge to the Vendor/Contractor, where the use of electric
tools is permitted.

The use of electric tools is not permitted on some works where construction takes place in an area covered
by specific rules and regulations and the Contractor shall make alternative arrangements.

Portable tools shall be 110V AC type fed from 110V centre tapped earth transformer so the maximum fault
voltage would be 55V or the portable tool may be double insulated. Restricted Current Device (RCD)
protection shall be installed for all portable tools having a tripping facilities of 30mA.

All connections, both to transformers and low voltage tools, shall be made via plugs and sockets of an
approved type. Taped jointed leads, taped twisted wires, and bare conductors, pushed into socket outlets,
are prohibited. Failure to observe this requirement will lead to the immediate isolation of unsatisfactory
equipment and repeated disregard for this requirement may result in the prohibition of all electric portable
tools.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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3.23 Emergencies

Prior to commencing work on site the Vendor/Contractor shall consult the Owner to establish the possible
nature of emergencies, procedure to be followed, and the whereabouts of assembly points in the event of
such emergencies.

3.24 Fixing of Equipment, Supports and Miscellaneous Steelwork

For fixing equipment and supports to steelwork/plant items, the methods and limitations detailed in Section
3.7.4.7 (Cable supports and fixings) shall apply.

Supports or fixings shall not be taken from, or fastened to pipes, pipe supports or pipe hangers, without
permission from the Owner.

All fixings shall be made into the brickwork and not into the bond between bricks. Where this is not
possible, because of the fixing centres of the equipment, then the upper fixings shall be into the brickwork.

All supports fixings, and cable access trays to externally located apparatus shall, so far as is possible, be
angled such as to shed rain away from the equipment.

3.25 Explosion-proof Equipment

The Vendor/Contractor shall ensure that only personnel who are fully conversant with the requirements
associated with the installation of explosion-proof equipment are employed in this type of work.

This type of equipment shall not be tampered with, modified or drilled, in any way whatsoever. Should
there be a need for modifications, the Owner shall be consulted.

After terminating and connecting the incoming cables, all flanges shall be checked for damage, cleanliness,
freedom from rust etc and if necessary cleaned, using a Tufnol (or similar) non metallic scraper. The
flanges shall be lightly greased with petroleum jelly, silicone grease, or other specified material. (The type
selected will be used throughout any particular installation).

Flanges shall be replaced and all studs, bolts etc replaced and correctly tightened. (NB All bolts are to be
of the correct type and are to be lightly oiled or greased before insertion). All flange gaps shall be checked
with feeler gauges of suitable lengths.

Denso (or equal) paste and tape shall be applied to the flanges of certain items of apparatus as decided by
the Owner. These will probably be items exposed to the weather, steam or water leaks etc., in applying
Denso tape the following rules shall be observed.

a) Tape shall not be applied to spindle or shaft gaps,

b) The gap for 1 inch (25 mm), 0.5 inch (12.5 mm) and 0.25 inch (6 mm) taped flanges joints shall
not exceed 4 thous (0.1 mm),

c) Tape shall be applied carefully so as to enclose completely all parts of the joint,

d) New tape shall be applied when existing tape is disturbed,

e) The tape shall be of a width suitable for the flange thickness, be in one continuous piece and
applied so as to avoid forming a water trap,

f) Tape shall not be applied to any joints on Group II C enclosures or

gasketted explosion-proof/weatherproof
 GENERAL ENGINEERING SPECIFICATION GES C.06
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equipment.

Gaskets on explosion-proof/weatherproof equipment shall be sound and secure.

Aluminium type paint shall not be used on explosion-proof equipment.

All the correct size and style of bolts shall be present for explosion-proof enclosure covers.

Where there is an obstruction within 1.5 inch (40 mm) of the edge of a flange the Owner shall be notified.

All stopper plugs shall be of the type requiring an hexagonal key or similar special tool. Where explosion-
proof equipment is installed in oxygen rich atmospheres the Vendor/Contractor shall refer to Section 3.36,
which outlines the procedure to be followed.

Explosion-proof equipment shall be treated as fully explosion-proof irrespective of the area in which it is
located (e.g. a flameproof pressure switch, even though it may be located in either a Zone 2 or safe area
shall be fitted with an explosion-proof cable gland).

3.26 Ferrules

Ferruling shall be in accordance with Section 3.7.4.8.

3.27 Good Housekeeping

In this context switchrooms, substations, analyser houses and other areas where considerable electrical
construction activities take place, shall be kept free of piles of cable ends, cable strippings, and other
accumulations of rubbish.

All equipment not being actively worked on shall have all doors closed and all covers firmly in position, to
prevent wire ends and rubbish finding their way in.

Tools and loose items must not be left or stored inside equipment or switchgear cubicles.

After completion of the terminations to any panel or item of equipment, such equipment shall be
thoroughly cleaned out, and all rubbish, spare ferrules etc removed.

Towards the end of the construction period, prior to the removal of essential access scaffolding, main
overhead horizontal cable runs shall be inspected, and arrangements made for any debris, planking, lagging
material etc to be removed.

Rubbish originating from electrical construction activities shall not clutter up roads, compounds, drains etc.
It shall be collected at some central point for frequent disposal as directed by the Owner. Empty cable
drums shall be returned to stores promptly by the Vendor/Contractor.

All outdoor equipment enclosures shall be cleaned out, and any connection stalks, and insulation carefully
cleaned and dried before final sealing.

Outdoor electrical equipment shall be sealed at all times when not being worked on.

3.28 Intrinsically Safe Equipment and Circuits

The Vendor/Contractors’ attention is drawn to the need for complete awareness of the requirements
associated with Intrinsically safe equipment and circuits.
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Care shall be taken to ensure that higher power levels do not degrade intrinsically safe wiring and circuits.
Care shall be taken when carrying out any testing to ensure that intrinsically safe circuits or equipment are
not subject to undue overvoltages by the injudicious use of unsuitable test equipment.

3.29 Inspection

Inspection shall be carried out in accordance with the Construction Contract and the relevant Specifications
or as directed by the Owner.

3.30 Instrument Supplies

Instrument cable entries shall be inspected as early as possible and any non standard cable entries shall be
brought to the attention of the Owner, so that suitable adaptors can be fabricated or obtained.

For control panel mounted instruments fed via flexible cables, plugs shall not be fitted to flexible cables
unless specifically requested by the Vendor/Contractor or the Owner. The plugs will be fitted later,
probably by others. (Early fitting of these plugs encourages possible loss/damage with the consequent
necessity for early replacement).

3.31 Instrument Control Room Panel Electrical Equipment

Control Room panels will normally be supplied complete with all the requirements known at the time of
ordering, regarding electrical equipment such as push buttons, indicator lights etc.

Items and connections shall be shrouded or boxed irrespective of the voltage. PVC or plastic boots will not
be acceptable. Shrouds, or boxes provided on site, for panel mounted items shall be constructed from
suitable gauge clear perspex and of adequate size. Boxes which depend on the front cover screws
sandwiching the control panel between the cover plate and box shall not be used unless the boxes are
otherwise fixed to the panel. Boxes shall be liberally sized.

Annunciator input alarm cable ferruling shall be in accordance with Section 3.5.

Oil tight type push buttons shall be located by the pin provided so that they can be tightened up properly.
The locating pin shall not be filed off.

All electrical equipment including conduit boxes etc., mounted on or behind Control Room panels shall be
marked and subsequently labelled indicating the Duty, Circuit and Circuit Voltage so that personnel will be
aware of the contents.

3.32 Lighting

The approved lighting layout drawings will indicate the approximate locations of lighting fixtures and
methods of fixing. The Vendor/Contractor shall determine the precise location of each fixture on site. The
precise location of lighting fittings shall be chosen to facilitate re-lamping, avoid interference with piping
or other mechanical equipment, and obtain as uniform an illumination as possible.

Any additional fluorescent tubes or fittings which the Vendor/Contractor is requested to supply shall be of
the 5 feet (1500 mm) 65 watt type, or as agreed with the Owner.

Lighting fittings positioned on walkways platforms etc shall be orientated so that important areas or items
e.g. stairs, stairways, landings, ladders, gauges, flowmeters, panel boards etc are adequately illuminated.
Where possible fittings in section, or areas shall be spaced symmetrically. The sizes, types and colours of
lamps to be fitted will be shown on the approved drawings or schedules.

In pump compounds and other areas at ground level, lighting fittings shall not be mounted more than 10.5
 GENERAL ENGINEERING SPECIFICATION GES C.06
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feet (3.25 m) above the level of the floor unless otherwise specified on an approved drawing.

In general, “Telescopic” or “Goose Neck” types of mounting shall not be used except in isolated cases
where no other method of fixing is practicable.

For the lighting of platforms, tops of tanks etc bulkhead fittings, fixed between handrails, and recessed so
as not to form an obstruction shall generally be used.

Overhead lights on walkways and platforms shall be not less than 2.2 yds (2 metres) and not more than
2.5 yds (2.25 m) above the walkway to facilitate re-lamping. Additionally, overhead lights shall be
mounted not less than 1 metre inside the edge of any such platform or walkway except on narrow
platforms, or walkways, less than 2.2 yards (2 m) wide, where they shall be mounted on the centre line of
the platform.

Bulkhead fittings shall not be mounted on or from the cell fan cowls at the top of cooling towers as
vibration shortens the lamp life considerably. Fittings shall be mounted off platform handrailing.
All supports and brackets shall be substantial and all fittings shall be adequately and firmly fixed. (See
Section 3.24 - Fixing of Equipment, Supports and Miscellaneous Steelwork and Section 3.40 - Painting).
All lighting fittings shall be located so that the chances of mechanical damage are minimised e.g. clear of
safety gates on access ladders.

The number of junction boxes used on lighting circuits shall be kept to a minimum. Junction boxes shall
not be installed adjacent to every fitting (for disconnection and fault finding purposes) unless shown on the
approved drawings. When junction boxes are used they shall be located in easily accessible positions not
more than 2.5 yds (2.25 m) above the working floor level, in-board of all platform edges and fitted with
permanent labels denoting circuit reference (See Section 3.33 - Labels).

Lighting switches, shall generally be mounted 1.6 yds (1.5 m) above floor level.

The Vendor/Contractor shall ensure that any explosion-proof lighting is installed in accordance with
Section 3.25 and that the special requirements applicable to cable gland installations for Zone 2 Restricted
Breathing Lighting Fittings, are met (See Section 3.7.3).

The Vendor/Contractor shall ensure that tungsten iodine or tungsten halogen type fittings are mounted with
the lamp axis horizontal. Lamps shall not be handled without their protective sleeve in place and heat sinks
not be discarded.

For Control Room and office type installations, circuit wiring shall not pass through lighting fittings unless
specified on an approved drawing.

Break joint rings of an approved colour shall be provided for all suspended fittings where the gallery or
ceiling rose, or ceiling plate, does not exceed the diameter of the ceiling box by 0.4 inches (10 mm).

Droppers from conduit boxes shall consist of Nominal Bore Mild Steel (NBMS) pipe screwed ¾ inch
(20 mm) Electric Thread (ET). Conduit shall not be used for droppers. In some instances, ball and sockets
joint covers may be required but they must not be used unless shown on approved drawings.

Angle blocks shall be provided for ceiling fittings which are suspended from sloping surfaces.

Ceiling roses shall be of the projecting moulded plastic type suitable for direct mounting on to conduit
boxes. Flexible pendant drops shall be circular heat resisting PVC insulated and sheathed cable of
approved colour, of sections not less than 1.96 k.c.mil (1 mm²). Lampholders shall comply with IEC
61184. Lampholders screwed direct to the conduit system shall be brass. Lampholders which are not
electrically continuous with the conduit system shall be insulated and complete with approved pattern
‘skirts’.

All lighting fittings shall be labelled, with the fitting references shown on the approved drawings. The type
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and style of labelling may vary from site to site. Labels shall be fixed adjacent to lighting fittings and not
on them, since fittings are frequently replaced.

3.33 Labels

3.33.1 General

As the labelling requirements may vary this subject shall be discussed with responsible works personnel
early in the project design stage and agreement reached as to the type, style and nomenclature etc required.

A schedule of labels for items of equipment will be prepared and issued by the design section and these
labels will be supplied to the Vendor/Contractor as free issue material.

Every item of electrical equipment (except motors which will be identified by a motor number fixed by the
manufacturer prior to despatch) shall be identified by an accurate and legible permanent label(s).

Warning Notices/Labels

Warning notices/labels shall be fitted wherever a hazard due to electrical shock is present. It will be the
responsibility of the Vendor/Contractor to locate them and the Owner will check the locations.

The notices/labels shall be of traffolyte and follow the requirements of the Identification labels except that
the inscription shall have black letters on a yellow background.

3.33.2 Detail

Indoor Locations

Labels on industrial equipment located indoors shall be fixed by nuts and bolts or self tapping screws.
Since explosion-proof equipment must not be drilled or interfered with in any way and it is undesirable to
drill Zone 2/Type N equipment, labels shall be fixed to adjacent surfaces by nuts and bolts or screws in
such positions that it is immediately obvious to which items of equipment the labels refer, or direct to the
equipment concerned with a good quality adhesive.

Outdoor Locations

Labels for equipment (including explosion-proof and Zone 2/Type N) located outdoors e.g. push buttons
and switches, shall be fixed to adjacent steelwork by nuts and bolts or self tapping screws in such positions
that it is immediately obvious to which items of equipment the labels refer. For small lighting circuit
junction boxes etc labels may be fixed direct to the item of equipment by the use of a good quality
adhesive.

The labelling requirements for distribution boards are detailed in Section 3.11 of this document.

If specified in the Purchase Order/Contract all items of explosion-proof equipment shall be identified by
additional labels, to facilitate recording of subsequent mandatory inspection.

All switches and socket outlets in Control Room and Office domestic type installations shall be labelled
(See Section 3.12).

Individual lighting fittings shall be labelled in accordance with Section 3.32.

The permanent labelling of additional electrical equipment added to Control Room panel fascias will be
carried out by Instrument personnel.

Temporary labels shall be provided for items of equipment not covered by the labels supplied to the
Contractor against the label schedule. Temporary labels shall be neat and legible and may be either Dymo-
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Tape or PVC Adhesive Tape suitably marked. Equipment shall not be written on with felt pens or other
markers.

Reference shall be made to Contract Specific Requirements for - "Electrical Identification Systems".

3.34 Motors

Motors will be located, fixed, and aligned by the Vendor/Contractor unless agreed otherwise with the
Owner.

The approved erection procedure and contract foundation drawings shall be followed.

The Vendor/Contractor shall carry out inspections of weatherproofing and insulation resistance tests as
required by the contract.

The insulation resistance may be affected during storage. If, on checking, the insulation is found to be less
than 1 megohm the motor must be thoroughly dried out (following the Vendor/Contractor's recommended
drying out procedures).

To prevent motor bearing damage it is considered essential to turn the motor shafts at least a quarter turn,
once per week, during the pre-commissioning period.

Cables shall enter terminal boxes from below to assist in the shedding of rain (see Section 3.7.3) and the
cores shall be connected in accordance with Section 3.7.4.8.

All gaskets shall be clean and in good condition.

To prevent internal damage due to moisture and the subsequent delay in drying out motors, before they can
be connected and run, the Vendor/Contractor shall ensure that his personnel are made aware of the
desirability of checking motors on site to ascertain that the terminal box and other entries are fitted with
temporary seals.

Any damaged, doubtful or obviously unsuitable boxes or terminal arrangements shall be brought to the
attention of the Owner immediately.

The Vendor/Contractor shall confirm with the Owner the phase sequence for connecting motors for the site
in question.

The Vendor/Contractor shall ensure that wherever possible, two cable core connections at the motor
terminal box can be interchanged, without stressing the connections or having to terminate again, should it
be necessary to reverse the motor direction of rotation.

In addition he shall confirm on an individual basis, the required direction of rotation (and connection
sequence) for all motors 175 hp (132kW) and above since it is difficult to reverse the direction of rotation
of these motors at a later date, due to the problems associated with the manipulation of the large cable cores
required for the larger LV motors and the time consuming activity of arranging suitable isolations etc., for
MV motors.

Thermistor connections shall not be disconnected, or shorted out, on any motor without the approval of the
Vendor/Contractor or the Owner. Only low voltage equipment, e.g. avometer shall be used for testing
thermistor circuits for continuity etc. Higher voltage equipment e.g. megger shall not be used.

Motors situated outdoors, except those of the flameproof weatherproof type, shall have their terminal box
flanges or joints suitably weatherproofed. The protection shall be Denso (or equal) tape except on motors
located in areas of plant where an oxygen rich atmosphere may be present, in which case self amalgamating
PVC tape shall be used.
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Where internal heaters are fitted to a motor these shall be kept continuously energised via a temporary
supply as soon as the motor is delivered. The Vendor/Contractor shall ensure that there is no delay between
the removal of the temporary supply and the connection, testing and energisation of the permanent heater
supply cable.

The Vendor/Contractor shall check that any motor terminal box desiccators are in good condition, (ie
crystals and indictor dry, and blue, not wet and pink). These are fitted to MV and higher voltages motor
terminal boxes.

The Owner's personnel concerned shall be responsible for the running of all motors.

3.35 Material: Collection, Storage, Safe-Guarding and Disposal of Surplus

The Vendor/Contractor will normally be supplied free issue with all major items of equipment, eg motor
control centres, pushbutton stations, lighting fittings etc. The supply of cable, and cable glands will be
decided by the Owner for each project.

The Vendor/Contractor may however, be responsible for the supply of minor items such as small brackets
and supports, tray plates, terminating lugs, nuts and bolts, ferrules etc and consumables such as solder,
jointing compound, Dymo Tape, etc to complete the works in question.

Where materials are issued free to the Vendor/Contractor, he shall be responsible for their collection and
transport from the Owner's Stores.

The Vendor/Contractor shall ensure that any Stores he established is a substantial weatherproof building
with door, or doors, which can be padlocked. Combined Electrical/Instrument Stores, or storage by the
Vendor/Contractor, of electrical equipment with any other equipment, is not permitted.

Material shall be stored in an orderly fashion so that it can easily be identified. The Vendor/Contractor
shall keep up to date records of the receipt, and usage of all free issue material and shall be in a position to
produce and justify these, to the satisfaction of the Owner. Towards the end of the construction period the
Vendor/Contractor shall prepare a list of all surplus material held, for cross checking with the Owner.

Once free issue materials have been issued to the Vendor/Contractor they are then his responsibility, and
any deficiencies, and damage (including weather damage) shall be made good at the Vendor/Contractor’s
expense, without prejudice to any target completion dates.

On this basis electrical equipment and material shall be examined as soon as possible following arrival at
the site. Checking should be carried out against respective orders and specifications and where deficiencies
or non-compliance with an order occurs details shall immediately be notified to the Owner.

Wherever possible, equipment shall be returned to its original packing for storage until required for use.

All surplus cable, scrap ends and cable drums shall be returned to the Owner's Stores or disposed of as
directed by the Owner.

3.36 Oxygen Rich Atmospheres

In areas where oxygen is present as part of the process, oil and grease shall not be used, or be present at all.
The extent of these areas will be shown on the approved drawing. In these areas, equipment eg push
buttons, pressure switches etc., shall be grease free. All flanges shall be adequately de-greased, under
controlled conditions and bolted up dry. Suitable de-greasing fluid, clean protective clothing and precise
instructions as to procedure will be provided by the Owner. In these situations, if weatherproofing is
considered necessary by the Owner, it shall be by the use of a self amalgamating PVC tape.
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3.37 Push Buttons/Motor Control Stations

The approximate locations of push buttons and other motor control stations will be shown on the approved
drawings. Precise location shall be determined on site by the Vendor/Contractor.

Generally speaking, motor control stations will be mounted on floor stands which will be supplied as free
issue material. Each station shall be labelled as Section 3.33.

Control stations shall not be bracketed off pipes or pipe flanges or located in such positions that they could
interfere with the dismantling or removal of pipework, pump or motor at some future date.

All push button spindles shall be free to move and lightly greased except where the use of grease is
prohibited. This may arise occasionally where oxygen is used in part of the process. (See Section 3.36).
For outdoor locations weatherproof type push buttons are purchased. Additional protection may be required
in some instances, at the discretion of the Owner (Refer also to Section 3.42.13).

Push buttons on control room panels shall be fitted and shrouded as detailed in Section 3.31.

Any special earthing requirements will be shown on the approved drawings.

3.38 Portable Tools

The Vendor/Contractor shall supply all the portable tools and associated equipment (e.g. drills, die sets etc)
that he requires. Owner's equipment will not be available. All portable tools shall be maintained in good
condition at all times to the satisfaction of the Owner.

Explosive powder actuated fixing tools shall only be used as defined in Section 3.7.4.7.

For the requirements for electric tools see Section 3.22.

3.39 Plant Hire

The Vendor/Contractor shall arrange to provide or hire such equipment as will expedite safe, satisfactory
and speedy completion of the job.

Safe working or completion of the job to programme shall not be prejudiced by lack of suitable equipment.

The Vendor/Contractor shall ensure that personnel operating or in charge of hired or other equipment are
experienced in its use and aware of any restrictions regarding the use of equipment in hazardous areas.

3.40 Painting

All painting and associated preparation shall be carried out by the Vendor/Contractor to the Owner's
satisfaction and fully comply with GES X.06.

All surfaces of brackets or metalwork supplied by the Vendor/Contractor shall be wire brushed to remove
all loose or flaking mill scale, rust or any other foreign matter until clean bare metal is exposed. The
surfaces shall then be painted with one coat of a good quality red lead primer.

Similar treatment shall be given to all surfaces of brackets and metalwork which are in contact with
galvanised or zinc sprayed metal except that a zinc chromate primer shall be used.

3.41 Programming

The Vendor/Contractor shall produce work and manning programmes to achieve the given completion date
 GENERAL ENGINEERING SPECIFICATION GES C.06
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as soon as he has established himself on site, and discussed the extent of the work with the Owner. The
programmes shall take account of the activities of other trades on the site and the Vendor/Contractor shall
give early warning of any required revisions. The Vendor/Contractor shall be required to attend progress
meetings and take an active part in the ensuing discussions.

The Vendor/Contractor shall keep up to date records of progress on the whole of the works on which he is
engaged to the satisfaction of the Owner. In addition to progress, these records shall show which of the
Vendor/Contractor’s personnel carried out each part of the installation.

3.42 Restriction of Work

Access

3.42.1 The attention of the Vendor/Contractor is drawn to the fact that his personnel will, in many instances, be
working alongside other trades and he shall ensure that his personnel allow them reasonable facilities and
working space.

3.42.2 Safety Precautions

The Vendor/Contractor shall ensure that both he and all his personnel are aware of the detailed system of
clearance certificates (permits to work) and fire permits in the plant area concerned.

Clearance certificates are required for all work in any area or on any item of plant which is not under the
direct control of the construction group (but is controlled by the Owner's personnel) Clearances may
occasionally be required for areas under construction group control (eg installing temporary underground
supply cables).

Clearance certificates will be issued by the Owner to the Vendor/Contractor, who will issue them to the
working groups.

“Fire permits” are required when work necessitating the use of blow torches, welding equipment, heaters,
drills, hacksaws or other possible means of ignition is to take place in an area where a fire or explosion
hazard may exist.

Twenty four hours notice of a request for a fire permit is required in the plant area and normally all fire
permits are cancelled each day necessitating their renewal on a day to day basis.

Fire permits will be issued by the Owner responsible for the plant area, to the Vendor/Contractor.

Padlocks and keys shall be supplied by the Vendor/Contractor for each and every item of equipment given
an electrical power supply to enable Testing, Inspection and Pre-Commissioning to proceed safely utilising
a permit system for each item of equipment being powered up.

3.42.3 Scaffolding

Scaffolding shall comply with the national Code of Practice governing its safe erection and to be to the
satisfaction of the Owner at all times.

Scaffolding shall not be modified or tampered with by the Vendor/Contractor’s personnel until completion
of the job in hand.

Where the Owner is responsible for scaffolding, requests for its erection shall be made to the Owner by the
Vendor/Contractor in good time to ensure its availability for use, without adversely affecting the
construction programme. The Vendor/Contractor shall allow other trades to use any such scaffolding
erected at his request and may, in turn, avail himself of any other scaffolding erected on the site.

The Vendor/Contractor shall draw to the attention of the Owner any onerous circumstances in the vicinity
 GENERAL ENGINEERING SPECIFICATION GES C.06
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of scaffolding, so that a decision can be made as to the necessity to earth the scaffolding, preventing it
becoming a conductor. Scaffolding located in hazardous locations shall be earthed regardless, preventing
the build up of static electricity.

3.42.4 Supervision

The Vendor/Contractor shall at the contractual stage, name his proposed supervisory staff and furnish
details of their previous experience. In the event of unsatisfactory construction progress the
Vendor/Contractor shall be prepared to reinforce or replace members of his work force.

3.42.5 Transformers

All MV transformers will be commissioned by the Vendor/Contractor and the Owner jointly.

The Vendor/Contractor shall ensure that transformers are correctly identified, positioned, cabled up, and
earthed, as shown on the approved drawing.

The Owner will arrange for disconnection, phase verification and insulation testing of feeder cables and
also the checking of protection current transformers (CTs) and the setting of protection relays by others.
Reference shall be made to the GES C.56.

3.42.6 Temporary Supplies

Temporary supplies shall not be installed or connected without the Owner’s permission. Temporary
installations shall be in accordance with BS 7375 - “Distribution of Electricity on Construction and
Building Sites”.

The Vendor/Contractor shall pay particular attention to any work carried out to provide temporary supplies
to huts, cabins, lighting circuits, instruments etc.

Temporary supply cables shall be neatly run and firmly fixed using plastic string, insuloid cleats or equal.
The use of wire ties is prohibited.

Temporary underground feeders shall not be installed in such a manner that they cannot be removed after
the plant is built.

If Owner has agreed at the contractual stage to supply electricity to the Vendor/Contractor for his huts etc,
it will be provided at the point and at the voltage, phase and frequency most convenient to the Owner. This
supply will normally be 480volts, 3 phase 60Hz or 208v/120 volts, 3 phase 60Hz or 380v/220 volts 3 phase
50Hz. The provision of all connections and apparatus required beyond the supply point shall be the
responsibility of the Vendor/Contractor. The Vendor/Contractor may be required to provide incoming
metering facilities for the supply, and if so, he will be notified at the contractual stage. The
Vendor/Contractor’s electrical equipment and wiring shall at all times comply with the appropriate
requirements, IEC and British Standard Codes of Practice. The Owner may require to inspect any part of
the installation at any time, particularly before supplies are connected.

The Vendor/Contractor shall maintain up to date records showing the duty, location, cable size and loading
of any temporary supplies which he installs.

3.42.7 Trunking

Trunking shall not be used outside buildings unless shown on the approved drawings.

Trunking will normally be supplied as free issue material but when the Vendor/Contractor is requested to
provide it, the type used shall be approved by the Owner.
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It shall be either sheet steel, glass fibre or plastic, having an overlapping well fitting lid which shall be fixed
securely.

For steel trunking copper continuity couplings or straps shall be fitted but shall not be relied upon solely for
earth continuity.

A continuous insulated cable earthing conductor of adequate size in relation to the main cables shall be run
in all trunking and for metallic trunking shall be bonded by means of copper clips.

The trunking shall be fixed securely and shall be protected where there is likelihood of mechanical damage
(e.g. from service pipes etc).

All junction and joints shall be smooth and snag free so that when cables are installed they will not be
damaged.

Where trunking is used to house power circuits the Owner shall approve the number of cables in any run of
trunking from the cable rating aspect.

Trunking shall be not more than 50% full on completion of construction, to cater for future requirements.

Cable cores associated with the same circuit shall be ‘combed’ and taped together at one metre spacing,
before inserting the trunking, to ensure a smooth twist free installation and assist later identification.

Where cables are glanded off into metallic trunking, paint etc shall be removed and star washers used to
ensure good earth continuity (See Section 3.7.3).

Cable retainer bridges of the trunking Vendor/Contractor's proprietary type, shall be inserted into inverted
horizontal or vertical trunking runs at frequent intervals such that the cables are held in place by the
retainers.

Joints or connections are not permitted in trunking and shall not be installed unless shown on approved
drawings or approved by the Owner.

3.42.8 Trace Heating

The heating cable shall be safeguarded against loss or damage, particularly on long pipe runs over open
ground.

Before commencing work on any part of the installation the length of pipe to be traced shall be measured
and compared with the length stated on the approved drawings and the Owner informed immediately of any
discrepancies.

The lengths of trace heating cable shall be accurately calculated to give the required degree of heating.
Their lengths shall not be shortened or increased without reference to the Owner.

The cable shall be carefully handled to avoid mechanical damage and shall be arranged on the piping,
piping supports, flanges, valves etc strictly in accordance with the instructions on the approved drawings.

The heating cable shall be fastened to the pipe with the trace heating Vendor/Contractor's banding, or
failing this, asbestos string, pending the addition of the lagging. Lagging wire or binding wire shall not be
used due to its tendency to cut into the cable sheath. Mid point and star point boxes shall be positioned as
shown on the approved drawings.

Care shall be taken to ensure that the correct temperature grade of cable seal is used. Where a brazed or
soldered seal is to be used, fire permits and clearance certificates will almost always be required. (See
Section 3.42.2).
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Where cables have been supplied with ‘cold ends’ brazed on by the cable Vendor/Contractor, these cold
ends shall not be cut or altered in any way without permission from the Owner.

Inadvertent breaks or damage to the cables shall be drawn to the attention of the Owner and repaired by the
use of suitable sleeved joints with seals of a temperature grade to be agreed.

Cables shall be tested for continuity and earth resistance and the readings obtained shall be within the
specified limits before lagging is commenced.

The Vendor/Contractor shall provide frequent attendance inspection as necessary during lagging to ensure
that lagging personnel are not displacing or damaging the heating cables. The type and design of any
clamps or binding rings being used by lagging personnel shall be closely inspected to ensure that they
cannot damage the heating cables.

The Vendor/Contractor shall fix notices (Danger - Electrical heating Cables) along the pipe line, and these
will normally be supplied as free issue material. The notices shall be fixed, on completion of the lagging at
22 yds (20 m) intervals on long lines and suitably shorter intervals on short lines and adjacent to all valves,
drain cocks or other take off points.

In the absence of any suitable adjacent established cable runs, small numbers of PVCSWAPVC or XLPE
cable from remote thermostats etc associated with the temperature control of the pipeline shall be strapped
on the top of the pipeline lagging.

3.42.9 Workmanship

All workmanship (and materials supplied by the Vendor/Contractor) shall be of first class quality
throughout to the satisfaction of the Owner. Good modern practices and techniques shall be adopted
throughout, and if the Vendor/Contractor is in any doubt as to the acceptability or otherwise of a proposed
intention, an opinion shall be sought from the Owner.

The Vendor/Contractor will be required to make good at his own expense, and without prejudice to any
programmed completion date, items of workmanship which in the opinion of the Owner are of poor or
unacceptable quality, together with the replacement at his own expense of any item of equipment which
cannot be re-used.

3.42.10 Works Rules

Before commencing work, the Vendor/Contractor shall confirm with the Owner the existence (or
otherwise) of any list of works rules applicable to the Vendor/Contractor’s employees.

In the event of such a list existing, the Vendor/Contractor shall familiarise himself with their rules and
ensure that his employees do likewise.

3.42.11 Workshop Facilities

Other than for minor works, the Vendor/Contractor shall provide a workshop, and workshop facilities
adequate for the size of the installation and the type of work envisaged.

3.42.12 Weatherproofing

Where necessary additional temporary protection shall be provided to guard against adverse conditions
which are present during the construction phase but will not be present when the plant is operational.

For the weatherproofing of cable glands, see Section 3.7.3.

 GENERAL ENGINEERING SPECIFICATION GES C.06
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For the weatherproofing of explosion-proof equipment, see Section 3.25.

For the weatherproofing of equipment in oxygen rich atmospheres, See Section 3.36.

For other items the Vendor/Contractor’s attention is drawn to the fact that whilst weatherproof equipment is
purchased for outdoor locations, as far as possible some items will require additional protection and non-
weatherproof equipment will be required to be weatherproofed. Requirements will be advised by the
Owner.

3.42.13 Electrolytic Corrosion

Measures shall be adopted to minimise electrolytic corrosion. Examples with some alternatives are given
below:

- When apparatus of one metal, say aluminium, is to mounted on a steel structure, stand-off washers
shall be used. The bolts, washers, and nuts may be galvanised or cadmium plated.

- Cable glands, other than aluminium glands, for installation into aluminium enclosures, may be
cadmium plated.

- Coatings of proprietary compounds, specially manufactured for the purpose, may be used between
dissimilar metals, with the agreement of the Owner.

4.0 CONTRACTOR'S DATA

4.1 Contractor's Responsibilities

The area and degree of responsibility vested in the Vendor/Contractor for the protection and maintenance
of electrical plant and equipment during construction and commissioning of the Works will be defined in
the contract documents for the particular project scope and implementation of these requirements shall be
agreed with the Owner before work is commenced.

4.2 Security & Safety

All work shall be carried out in accordance with GES C.03.

Serious consequences can arise due to accidental damages to and/or inadvertent operation of equipment
associated with operating plant, or through interference, consequently every precaution shall be taken to
prevent such occurrences. Should they take place, the Owner shall be informed immediately. It is important
that any related or immediate subsequent action necessary should only be undertaken on receipt of specific
instructions from the Owner unless the action needed is obvious and can be carried out safely, e.g. fighting
a fire with the correct means.

5.0 QUALITY ASSURANCE, INSPECTION TESTING & COMMISSIONING

5.1 Quality Assurance

The Vendor/Contractor shall offer at the time of Tender, the proposed quality assurance/control (QA/QC)
systems for approval by Vendor/Contractor or the Owner.

5.2 Inspection, Testing & Pre-Commissioning

 GENERAL ENGINEERING SPECIFICATION GES C.06
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The complete works shall be subject to inspection and test for compliance with this specification,
specifications listed below and practices referred to in the contract documents.

GES C.54 Field Commissioning of Instrument Systems

GES C.55 Field Installation Calibration and Testing of Instruments

GES C.56 Electrical Commissioning

GES C.60 Plant Pre-Commissioning, commissioning and Start-Up Guidelines

After erection of the equipment and completion of the electrical and instrument installation and
connections, the Vendor/Contractor shall carry out Inspection, Testing and Pre-Commissioning the
complete Electrical and Instrument installation.

`Inspection' shall mean thorough visual and physical inspection of the equipment and materials, to ensure
that the installation has been carried out in accordance with the contract documents and that a high standard
of workmanship has been achieved. `Testing' shall mean all the tests normally carried out prior to Pre-
commissioning and energisation. `Pre-commissioning' shall mean all final checks, tests and energisation
necessary to ensure that each circuit and its devices perform their required functions satisfactorily.

Care shall be taken to identify and disconnect equipment which could be damaged by the high voltages
used during insulation tests and measurements. Prior to undertaking Inspection, Testing and Pre-
commissioning, the Vendor/Contractor shall submit his proposed procedures to the Owner for approval
before work begins. These procedures should describe in detail the method to be employed for Inspection,
Testing and Pre-commissioning of each type of equipment, the record sheets to be used and the maximum
and minimum expected test values.

The Owner reserves the right to witness all tests and shall be given adequate notice prior to their
commencement. Certain tests may also be witnessed by an independent inspection authority. Accurate
records shall be kept of all checks and tests. Record sheets shall be signed by the Vendor/Contractor's
representative and shall be approved by the Owner.

Record sheets shall be retained by the Vendor/Contractor for inclusion in the test and inspection dossier to
be handed to the Owner upon completion of the contract. The Vendor/Contractor shall provide all test
equipment, appliances, instruments (calibrated to international standards), labour and other facilities
required for testing.

When specifically required, the Vendor/Contractor's representatives will be available for supervision
guidance for the testing and pre-commissioning of major items of equipment. This does not relieve the
Vendor/Contractor in any way from the responsibility of providing competent and suitably qualified
personnel, nor of the completion of test records. The abbreviated inspection and tests listed below are
indicative only and are not intended to define the limits of any activities the Vendor/Contractor may be
required to carry out.

Inspection of the equipment and materials shall include but not be limited to:

(a) Compliance of the installation with the Contract documents.

(b) Cleanliness of the equipment

(c) Correctness of identification labels, manufacturers nameplates, operation and warning notices and
hazardous area equipment certification details.

(d) Correctness of equipment component parts to 'Approved for Construction' and to

Vendor/Contractor's drawings.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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(e) Correct equipment degree of protection, particularly with regard to cable gland entries.

(f) Configuration, alignment and tightness of fixing and holding down bolts.

(g) Earth bonding of equipment

(h) Mechanical and electrical interlocks, door and isolating handle interlocks, castell key interlocks
etc.

(i) Padlocking facilities.

(j) Correctly fitted guards and protective covers.

(k) Correctness of circuit details with 'Approved for Construction' drawings.

(l) Compliance with hazardous area certification requirements.

Testing and Pre-commissioning of the equipment and materials shall include but not be limited to:

(a) General

Insulation resistance, high voltage tests, polarity, earth loop impedance, continuity.

(b) Switchgear/MCCs

Primary and secondary injection tests of current and voltage, transformers and protection,
relaying/instrumentation, operational/functional tests of closing, tripping alarm and indication
systems. Adjusting protection relays to the settings given, once testing is satisfactorily completed.

(c) Motors

Direction of rotation (uncoupled from the load). No load run check bearings and alignment.

(d) Lighting

Illumination levels

Note:

All Instruments and apparatus used in the performance of the tests shall have been calibrated to an agreed
standard at a laboratory of National standing within a period of 15 months of the test date. The cost of
carrying out such calibrations shall be borne by the Vendor/Contractor in all cases.

Reference shall be made to GES C.56, for more detailed information regarding Pre-Commissioning. See
also GES C.60 which gives information regarding trades excluding Electrical and Instrumentation and GES
C.54 which covers the field commissioning of instruments.

5.3 As Built Drawings

5.3.1 Any changes to design drawings by the Vendor/Contractor shall be approved by the Owner.
 GENERAL ENGINEERING SPECIFICATION GES C.06
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5.3.2 These changes shall be marked in red pencil or ink onto "As Built" drawings by the Vendor/Contractor and
submitted to the Owner.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.01

FIRE AND GAS ALARM SYSTEMS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES H.01
FIRE AND GAS ALARM SYSTEMS Page 2 of 46
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 6
2.3 Abbreviations 7

3.0 DESIGN 8

3.1 Codes and Standards 8

3.2 Fundamental Considerations 9
3.3 General Applications 12
3.4 Specific Applications 29

4.0 MATERIALS 36

5.0 SYSTEM RELIABILITY 36

5.1 General 36
5.2 Gas Detector Reliability 38
5.3 Fire Detector Reliability 38

6.0 INSTALLATION 40

7.0 INSPECTION 40

7.1 Procedures 40

8.0 TESTING 40

8.1 Statutory Tests 40

8.2 Test Procedures 41
8.3 Test Certificates 41
8.4 Site Acceptance Test Requirements 41
8.5 Test Equipment 42

9.0 DOCUMENTATION 42

9.1 Introduction 42
9.2 Schedules and Reports 43
9.3 Data and Calculations 43
9.4 Drawings 43
9.5 Final Records, Documents and Manuals 44
 GENERAL ENGINEERING SPECIFICATION GES H.01
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SEC TITLE PAGE

10.0 PREPARATION FOR SHIPMENT 45

10.1 Painting and Coatings 45

10.2 Spares 45
10.3 Packing and Storage 45
10.4 Shipping 46
10.5 Warranty 46
 GENERAL ENGINEERING SPECIFICATION GES H.01
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification is in the nature of a philosophy document and it covers the minimum requirements for
the conceptual design of detection and alarm systems which are to be provided to give alarm in the event of
a potentially dangerous situation arising from fire or from gas.

Its prime purpose is to ensure that the systems specified:

(a) are appropriate to the risks present and

(b) will give appropriate alarms.

This specification defines WHAT TO PROVIDE.

For details on HOW TO PROVIDE, reference shall be made to GES J.24.

1.1.2 This specification applies to equipment for refineries, onshore oil and gas installations and processing
facilities.

1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.4 In the event of any conflict between this specification and any other documentation issued by the Owner, or
with any of the applicable codes and standards, the Vendor/Contractor shall inform the Owner in writing
and receive written clarification before proceeding with the work.

1.1.5 This General Engineering Specification will form part of the Purchase Order/Contract together with the
Data Sheets, drawings or other attachments.

1.1.6 This specification is confined to conceptual design. For detailed requirements on detailed design, hardware
selection, materials, manufacture, inspection, testing, documentation, packing and shipping, reference shall
be made to GES J.24.

1.1.7 This specification does not include the following:

(a) Special process plant

Process plant which handles chemicals other than produced hydrocarbons (e.g., sulphur, chlorine,
mercaptans, ammonia, glycol, methanol).

(b) Manned offshore platforms

Offshore oil and gas drilling and/or production platforms which have sleeping accommodation on
board and which may require higher levels of safety than those defined by this specification.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES H.06 Fixed Water Spray Systems

GES H.07 Fire-fighting Facilities for Storage Tanks

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GES H.08 CO2 and Halon Substitute Systems

GES J.24 Fire and Gas Instrumentation

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Angstrom

A unit of length used to express radiation wavelengths. 1 Angstrom = 10-10 metres.

Background gases

Gases present in an area under surveillance other than those intended to be measured or detected.

Eutectic element

A mechanical element (e.g. link, lever or plug) which is made from a material of such composition that, on
being subjected to high temperatures, it changes from solid to gas without going through a liquid phase.
The purpose of using such special materials is to give rapid failure of the element in the event of fire in
order to immediately initiate some executive action (e.g. releasing pressure to activate an alarm or
extinguishing system).

Flame

Radiant energy emitted by fire, sub-divided for practical purposes into:

(a) ultra-violet, outside human vision, at wavelengths below 4000 Angstroms;

(b) visible to humans, at wavelengths of 4000-7700 Angstroms;
(c) infra-red, outside human vision, at wavelengths above 7700 Angstroms.

Frangible bulb

A heat detection element made of a special glass mixture which fails (thus initiating an alarm signal and/or
release of pressurised fire-fighting agent):

(a) at a prescribed fixed temperature (the usual mode of operation);

(b) by being struck by an electronic hammer (to also permit manual activation of the system).

Fusible element

In the fire protection industry, this term is taken to mean the same as “eutectic element”.

Lower explosive limit (LEL)

The lowest concentration of a flammable gas in air which is capable of sustained burning if ignited, usually
expressed in percentage by volume (e.g. methane LEL = 5.3 %).
 GENERAL ENGINEERING SPECIFICATION GES H.01
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Poisoning

The contamination of catalytic-type sensors by certain chemical elements or compounds (mainly silicones
and tetraethyl lead), which can result in reduction or complete loss of sensitivity.

Smoke

Visible or invisible particulates, fire gases and aerosols produced during combustion.

Thermal lag

The difference between the temperature of a fire and the temperature of a heat detection device placed in
that fire, proportional to the rate at which the temperature is rising.

Threshold limit value (TLV)

Threshold limit values refer to airborne concentrations of hazardous substances.

Threshold limit value - time weighted average (TLV-TWA)

The time-weighted average concentration (usually expressed in ppm by volume) of a potentially hazardous
substance (e.g. toxic gas) which may be present in the work-place atmosphere for an eight hour working
day or 40 hour working week and to which nearly all workers may be repeatedly exposed day after day
without adverse effect.

Threshold limit value - short term exposure limit (TLV-STEL)

The maximum concentration (usually expressed in ppm by volume) of a hazardous substance which may be
present in the work-place atmosphere for a fifteen minute working period without workers suffering from
irritation, chronic or irreversible tissue change, or narcosis of sufficient degree to increase accident
proneness or impair self-rescue, provided that:

(a) no more than four excursions are permitted per day;

(b) there is at least 60 minutes between exposure periods;
(c) the daily TLV-TWA is not exceeded.

The STEL should be considered a maximum allowable concentration, not to be exceeded at any time
during the 15 minute excursion period.

Upper explosive limit (UEL)

The highest concentration of a flammable gas in air which is capable of sustained burning if ignited,
usually expressed in percentage by volume (e.g. methane UEL = 14 %).

Zone

A defined area within the protected premises (e.g. an area from which a signal can be received, an area to
which a signal may be sent or an area in which a form of control can be executed).

2.2 Contractual

The commercial terms used in this specification are defined as follows:

 GENERAL ENGINEERING SPECIFICATION GES H.01
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Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

2.3 Abbreviations

1oo1 One out of one (voting mode)

1oo2 One out of two (voting mode)
1ooN One out of more than two (voting mode)
2ooN Two out of more than two (voting mode)

ac alternating current

A/C Air Conditioning

CO2 Carbon dioxide

dc direct current

ESD Emergency Shut Down

GA “General Alarm”

H2S Hydrogen Sulphide

IR Infra-Red

LEL Lower Explosive Limit

LOS Line Of Sight

 GENERAL ENGINEERING SPECIFICATION GES H.01
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MAC Manual Alarm Callpoint

ppm parts per million

PSD Process Shut Down

STEL Short Term Exposure Limit

TLV Threshold Limit Value

TWA Time-Weighted Average

UV Ultra-Violet

VDU Visual Display Unit

WG Water Gauge

3.0 DESIGN

3.1 Codes and Standards

3.1.1 Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and Standards
at the time of the order should be used.

3.1.2 The design shall comply with this specification and the following Codes and Standards:

Institute of Petroleum (IP)

Model Code of Safe Practice:

Part 3 Refining
Part 4 Drilling & Production Safety Code for Onshore Operations
Part 9 Liquefied Petroleum Gas
Volume 1 - Large Bulk Pressurised Storage and Refrigerated Storage
Part 14 Inspection and Testing of Protective Instrumentation Systems
Part 19 Fire Precaution at Petroleum Refineries and Bulk Storage Installations

British Standards Institute (BS)

BS 5445 Components of Automatic Fire Detection Systems

BS 5446 Specification for Components of Automatic Fire Alarm Systems for Residential Premises

BS 5839 Fire Detection and Alarm Systems in Buildings

BS 6020 Instruments for the Detection of Combustible Gases

BS 6266 Code of Practice for Fire Protection for Electronic Data Processing Installations

BS 6959 Code of Practice for Selection, Installation, Use and Maintenance of Apparatus for the
Detection and Measurement of Combustible Gases
 GENERAL ENGINEERING SPECIFICATION GES H.01
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BS 7273 Code of Practice for the Operation of Fire Protection Measures

Part 1: Electrical Actuation of Gaseous Total Flooding Extinguishing Systems

American Petroleum Institute (API)

API RP 55-81 Recommended Practices for Conducting Oil and Gas Production Operations
Involving Hydrogen Sulphide, Section 7:

Guidelines for the Evaluation and Selection of Continuous Hydrogen Sulphide

Monitoring Equipment.

API 555 Process Analyser

API 2510 Design and Construction of LP-Gas Installations at Marine and Pipeline
Terminals, Natural Gas Processing Plants, Refineries and Tank Farms.

API Publ 2510A Fire Protection Considerations for the Design and Operation of Liquefied
Petroleum Gas (LPG) Storage Facilities

National Fire Protection Association (NFPA)

NFPA 70 National Electrical Code

NFPA 72 National Fire Alarm Code

NFPA 75 Protection of Electronic Computer/Data Processing Equipment

NFPA 101 Code for Safety to Life from Fire in Buildings and Structures

NFPA 231C Rack Storage of Materials

NFPA Fire Alarm Code Handbook

Instrument Society of America (ISA)

ISA RP 12.13 Installation, Operation, and Maintenance of Combustible Gas Detection

Instruments
Pt 2

ISA RP 12.15 Installation, Operation, and Maintenance of Hydrogen Sulphide Detection

Instruments
Pt 2

3.2 Fundamental Considerations

When determining the type of fire and gas detection systems required to initiate alarm, the decision process
shall be based on due attention to the following fundamental considerations.

3.2.1 Need for Alarm Systems

(a) Alarms required

For all locations where fire and/or gas hazards could arise which might subject persons, capital
assets, or valuable products or consumables to unacceptable risk, alarm systems shall be provided
together with manual and/or automatic methods of initiating these alarms.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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(b) Basis for alarm

When required, detection and alarm systems shall be selected on the basis of specific incident
scenarios, for which they shall ensure rapid, reliable detection, in sufficient time to give alarm and
take appropriate action, whilst at the same time ensuring a practical and economical approach.

They shall continuously monitor fire and gas hazards and the status of automatic fire extinguishing
systems; they shall also themselves be continuously monitored for fault and hazardous condition.

(c) Alarms not required

No alarm systems (and consequently no systems for manual or automatic activation) are required
for locations where the risk of loss or damage from fire and/or gas is acceptably low.

For example, risks associated with loss of containment from cross-country pipelines carrying:

either non-toxic product;

or toxic product through uninhabited areas;
open drum storage where spacing is sufficient to ensure that, should a fire occur, the
resulting loss would be minimal.

(d) Marginal cases

Inevitably there will be marginal cases which cannot be decided in a general specification. To
determine the requirements in such cases, those preparing the conceptual design shall have an
adequate overview of the installation to be protected and visit the installation if it is existing.

In cases of doubt, detection and alarm systems shall be provided.

(e) Review by Owner

The exact location of sensors and the Cause and Effect Charts shall be reviewed by the Loss
Prevention Department, the Operations Department and any specialist Technical Services
Department of the Owner.

For existing facilities, the exact location of sensors shall be determined after a site visit.

The detector location plan drawing shall include all indicators, alarms and required warning
devices and major signs.

3.2.2 Principal Indicators of Danger

(a) Single principal indicator

In choosing the system required for a given scenario, the most reliable and most rapidly detectable
indication that an incident has occurred shall first be identified.

To achieve this, appropriate account shall be taken of the following:

A flammable gas which contains significant quantities of toxic gas presents two distinct dangers:

(a) toxicity, the danger typically arising in the ppm range

(e.g. H2S with TLV = 10 ppm and STEL = 15 ppm);
 GENERAL ENGINEERING SPECIFICATION GES H.01
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(b) flammability, the danger typically arising in the percentage range (e.g. methane with 5.3
% LEL).

With different types of flammable material giving off different amounts of these products a fire
can produce abnormal levels of:

(a) heat (increased temperature);

(b) smoke (visible and invisible products of combustion);
(c) flame (radiation).

(b) Multiple principal indicators

If it is not possible to monitor all significant risks in a given location with only one type of
detection then more than one type shall be specified.

For example:

with flammable gas which has a significant toxic content, both toxic and flammable gas
detection shall be specified;

for enclosed gas-fuelled equipment, both flame detection (to detect gas fires) and heat
detection (to detect lubricating oil fires) shall be specified.

3.2.3 Spatial Coverage

Conceptual designs shall take appropriate account of the fact that detection techniques fall into the
following three categories, listed here in order of decreasing spatial coverage:

space-type, monitoring throughout a three-dimensional space (e.g. the cone of sight of a flame
detector);

line-type, monitoring along a narrow line (e.g. the straight line of sight of a laser gas detector or
the - not necessarily straight - line of a heat detector cable or pneumatic tube);

spot-type, monitoring at a single spot only (e.g. a heat-sensitive eutectic element).

As far as practicable, the cost of protection systems shall be minimised by specifying the category giving
the largest spatial coverage, provided that adequate reliability and speed of response can be ensured.

3.2 4 Required Speed of Response

The speed of response of any alarm system shall be directly related to the type and degree of hazard which
can arise and the speed with which it can develop from "Alert" to "Danger" level.

The greatest need for speed arises in the event of confirmed loss of containment of highly toxic gases, in
which case extreme danger can be imminent and personnel in the area must be very quickly warned to
evacuate.

Gases which are flammable but not toxic must be detected in sufficient time to minimise explosion risk.

Compared with serious accidental gas releases, fires do not always require the same urgent response (e.g. a
smouldering electrical fire will take some time to reach dangerous proportions).
Particular attention shall be paid to the speed of response to manual alarms as:
 GENERAL ENGINEERING SPECIFICATION GES H.01
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they give no information on the type or level of hazard identified;

the hazard may be present for some time before the alarm is raised.

3.2.5 Voting

The need for a voting system to control alarms and automatic response will depend on the reliability of
detection. Prime requirements for detectors to automatically initiate executive actions are that the detectors:

(a) should reliably (and with reasonable accuracy) detect a hazard if it is present at the detector head;

(b) should not announce the presence of a hazard if there is no hazard or if it is insignificant.

If (a) can be achieved but not (b) then a 1oo2 (one out of two) voting system shall be used. If neither can be
relied upon then a 2ooN (two out of more than two) system shall be specified.

Unless otherwise specified, different types of gas and/or fire detector installed in the same area shall vote
independently of each other. (One exception to this is systems provided for the protection of hooded
turbines. See Section 3.4.2.).

As gas, smoke and flame detectors are likely to give false alarms, they shall always be specified in voting
mode unless otherwise stated.

3.2.6 Post-Detection Reinstatement

Components of detection systems are designed to be re-usable or replaceable as follows:

(a) re-usable, provided that the incident can be dealt with before excessive damage occurs:
e.g self-restorable (e.g. bi-metallic strips) and manually restorable (e.g. solenoid valves in fail-safe
systems);

(b) replaceable, because they are, by design, destroyed by the process of fire detection
e.g. pneumatic tubing, eutectic elements, frangible bulbs.

Preference shall be given to re-usable components unless cost and/or reliability dictate otherwise.

3.3 General Applications

All appropriate spaces and critical equipment shall be monitored continuously and automatically for fire
and gas. This requires detectors of different types, some of which must be programmed to take executive
action.

In addition, manual activation of alarms shall be provided.

3.3.1 Manually Activated Callpoints (MACs)

MACs shall be strategically located:

in the vicinity of but at a safe distance from the potential “Danger” area;
along the most likely escape route from the “Danger” area.
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3.3.2 Gas Detection - General

(a) Gas types

The specification of conceptual designs shall divide gas hazards into two distinct types:

toxic gas, potentially hazardous when it exceeds its TLV-STEL;

flammable gas, potentially hazardous when it approaches its LEL.

(b) Principal modes of gas detection

Principal modes of gas detection include:

monitoring gas leaks by sensing the drop in pressure:

with low reliability,
not capable of detecting in the ppm range.

Not to be specified.

monitoring the acoustic emissions of leaking gas:

with low reliability,
not capable of detecting in the ppm range.

Not to be specified.

monitoring for spectrographic absorption by laser beam:

potentially offering considerable advantages in terms of minimising hardware and
maintenance.

To be specified only if specifically called for in the Purchase Order/Contract;

monitoring at a point:
detecting only gas which comes into contact with the detector head,
able to monitor a space by:
monitoring a series of points;
continuously extracting an air sample from an air outlet duct and monitoring the sample.

To be specified unless otherwise stated.

(c) Combined gas detection

When both toxic and flammable gases need to be monitored, this shall be done by separate
detector heads, each specially selected for the particular gas.

(d) Gas detector locations

The required number and location of detectors shall be decided on the basis of:

gas characteristics (e.g. density, toxicity, flammability);

plant layout;
 GENERAL ENGINEERING SPECIFICATION GES H.01
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gas dispersion calculations (which take into account such factors as pressure, probable
leak size, local flow patterns, prevailing wind directions and ambient environmental
conditions);
speed of gas detection and annunciation once gas has reached the detector head;
speed of shutdown/ blowdown of gas sources;
detector system reliability and maintainability (too many heads usually giving too many
spurious alarms and becoming more difficult to maintain).

Particular attention shall be paid to providing gas detectors to monitor locations:

where gas may accumulate;

between gas plant and potential ignition sources, preferably closer to the gas sources.

In the case of few potential points of leakage, sensors shall be placed around the equipment concerned.

In the case of many potential points of leakage, detectors shall be placed around the plant area, preferably
downwind (e.g. at 4m to 6m spacing).

In general, the location of detectors in the immediate vicinity of probable minor sources (e.g. control valve
stems, sample points, drainage points, instrument gas vents and flanges) shall be avoided.

As detectors are more likely to be effective where gas would be restricted on release, use shall be made of
collector hoods where practicable.

In the open, gas can best be detected by an array of point-type detectors (until such time as laser beam
detection systems have been proven to give the required reliability).

Since, even indoors, air flow past sensor heads tends to increase drift, shorten sensor life and affect
sensitivity, sensors shall (as far as possible) be installed in relatively draught-free areas, or protected from
high air speeds by deflectors.

Gas detectors shall be located in the air intakes of:

force-ventilated or pressurised non-hazardous areas;

equipment cooling/combustion air systems if there is the opportunity for gas ingestion from
neighbouring areas.

Unless otherwise specified, the installation, operation and maintenance of flammable gas detectors and H2S
detectors shall be in accordance with the following standards respectively:

ISA RP 12.13 Part 2;

ISA RP 12.15 Part 2.

Gas detector locations shall not hinder routine day-to-day operations. If, however, optimum detector
locations would interfere with maintenance then the design shall be such that the detector can be readily
removed and replaced. Despite the inconvenience which this may cause during maintenance, it is shall be
classed necessary. (The alternative of locating the detectors further away from the risk to facilitate
maintenance activities is not acceptable.)

3.3.3 Toxic Gas Detection

(a) Toxic gas detector types

The following toxic gas detector types may be specified as appropriate:

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Semi-Conductor Resistance

These devices are generally more resistant to extreme temperature and vibration than the
electrochemical cells.

Electrochemical cell

Electrochemical cells offer a higher accuracy than semiconductor types, but have a shorter
working life.

Impregnated Paper

Shall not be specified as a principal H2S detection method.

(b) Toxic gas detector settings

When choosing toxic gas detector settings, there are two possible approaches:

(a) to set all detectors at the same level and choose:

1ooN for “Alert” and 2ooN for “Danger”

(b) install detectors which can alarm at two levels and choose:
1ooN at the lower level for “Alert” and 1ooN or 2ooN at the higher level for
“Danger”.

In addition to the above considerations, a decision has to be made on whether to base the set levels
from the following:
TLV-TWA (e.g. 10 ppm for H2S);
TLV-STEL (e.g. 15 ppm for H2S).

Unless otherwise specified, for H2S systems:

“Alert” shall be initiated by one detector at 6 ppm;
“Danger” shall be initiated by two detectors at 15 ppm.

(c) Toxic gas detector speed of response characteristics

An essential consideration in specifying any gas detection system is the speed of response at the
concentration levels to be detected (whereby slow response at low concentrations does not
necessarily mean slow response at high concentrations).

The response time of the semiconductor toxic gas sensor is typically in the order of one minute for
output of 50 percent of the measured concentration.

Electrochemical cells offer about three times faster response than semiconductor types.

(d) General application

Fixed toxic gas detectors, positioned to detect lighter and/or heavier than air gases as applicable,
shall monitor all areas:

which contain significant potential sources of toxic gas emission;

in which the gas could accumulate.
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When considering the density of the gas to be detected, appropriate account shall be taken of
whether the toxic gas is:

essentially in its pure state (in which case its own density will apply);
a minor component in a gas mixture, in which case the average density will apply (e.g.
for the positioning of H2S detectors to monitor produced gas comprising predominately
methane, the density of the methane (considerably lighter than air) will apply).

(e) H2S Gas Detectors

Refer to Section 3.4.9

3.3.4 Flammable Gas Detection

(a) Flammable gas detector types

The following flammable gas detector types may be specified as appropriate:

Catalytic Combustion (Pellistor)

The catalytic combustion type is the most widely used type of gas detector and shall generally be
specified.

It responds to all flammable gases in air (though response can vary with the catalyst used and the
type of gas).

The calibration gas specified shall be the major component of the gas mixture to be monitored to
which the detector is least sensitive. (Methane generally thus becomes the calibration gas.)

Semiconductor Resistance

The semiconductor sensor requires continuous heating to prevent water molecules becoming
adsorbed and de-sensitising it.

(b) Flammable gas detector settings

Flammable gas detectors shall have two adjustable alarm levels which can be set between 0 to
100% of the lower explosive limit (LEL), with:

the lower level (“Alert” level) generally set at 25% LEL;

the upper level (“Danger” level) generally set at 50% LEL.

For the special case of gas turbine monitoring, the above settings shall be 15% and 25%
respectively unless otherwise specified.

(c) Flammable gas detector speed of response characteristics

An essential consideration in specifying any gas detection system is the speed of response at the
concentration levels to be detected (whereby slow response at low concentrations does not
necessarily mean slow response at high concentrations).

Generally, the response time of semiconductor sensors is slower than that of the pellistor types.

(d) General application

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Fixed flammable gas detectors, positioned to detect lighter and/or heavier than air gases as
applicable, shall monitored all areas which contain significant potential sources of flammable gas
emission or in which the gas could accumulate.

3.3.5 Fire Detection - General

(a) Fire types

For each fire scenario to be analysed, the conceptual design shall be based upon which of the
following will be the prime indicators of a potentially hazardous situation:

1. heat;
2. smoke;
3. flame;
4. heat and smoke;
5. heat and flame;
6. smoke and flame;
7. heat, smoke and flame.

Fire detection systems shall preferably be based upon alternatives 1-3 above (i.e., on one of the
fire phenomena only).

In situations where this cannot guarantee adequate reliability and speed of response, alternatives 4-
6 above shall be specified.

Alternative 7 above shall be specified only if called for in the Purchase Order/Contract.

(b) Principal modes of fire detection

The following basic methods of fire detection may be specified unless otherwise stated:

1. heat detection:

monitoring absolute temperature at a point;

monitoring rate-of-rise of temperature at a point;
monitoring absolute temperature at intermittent points along a line;
monitoring absolute temperature at all points along a line.

2. smoke detection:

monitoring smoke at a point;

monitoring smoke along a straight line of sight;
monitoring smoke throughout a space by sucking air samples through a monitored point.

3. flame detection:

monitoring flame throughout a conical space or a series of conical spaces.

(c) Combined fire detection

Combined fire detectors are devices which:

respond to more than one of the fire phenomena (e.g. a combination of a heat rate-of-rise
and optical smoke detection in a single device);
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employ more than one operating principle to sense one of the fire phenomena (e.g. a
combination of rate-of-rise and fixed temperature heat detection).

Combined fire detectors may be specified.

(d) Fire detector locations

General

Fire detector locations shall not hinder routine day-to-day operations. If, however, optimum
detector locations would interfere with maintenance then the design shall be such that the detector
can be readily removed and replaced. Despite the inconvenience which this may cause during
maintenance, it shall be classed necessary. (The alternative of locating the detectors further away
from the risk to facilitate maintenance activities is not acceptable.)

Fire detection (usually flame detection) shall be specified wherever it is necessary to specify
flammable gas detection.

Heat detector locations

For heat detectors located indoors, NFPA 72 shall be used as a principal reference with the
interpretation provided by the NFPA Fire Alarm Code Handbook, taking full account of the
manufacturers’ recommendations.

Heat detectors located outdoors shall be placed directly above the location where the fire is most
likely to occur.

Smoke detector locations

Smoke detectors are primarily specified for indoor application with low air flows. Consequently,
NFPA 72E, which contains much detail on the location of smoke detectors in buildings, shall be
used as the principal reference.

With smoke detectors, careful choice of location is required to:

avoid spurious alarms (when there is no fire) due to convection of air;

ensure successful detection and alarm (in the event of fire) despite possible smoke
turbulence or stratification.

If detection of smoke in an air supply system is required, the detectors shall be listed for the air
velocity present and shall be located in the supply air duct downstream of both the fan and the
filters.

Flame detector locations

As flame detectors are cone-of-sight devices, they shall always be located such that there is
minimum risk of them being blinded by:

foreign matter settling on and thus obscuring the lens;

obstacles obscuring the cone of view.

Where obscured views cannot be avoided, additional detectors shall be specified to ensure the
required spatial coverage.
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When located outdoors, flame detectors shall be shielded to prevent diminishing sensitivity by
such environmental factors as rain and dust accumulation.

3.3.6 Heat Detection

(a) Heat detector types

The following types may be specified as appropriate:

Fixed temperature detectors

This type, which responds when the temperature of its operating element reaches a predetermined
value (but usually suffers from thermal lag), includes:

bimetallic (spot-type, automatically self-restoring when the temperature drops below the set
point);
frangible bulb (spot-type, replaceable);
eutectic element (spot-type, replaceable);
line detection, achieved by means of:

specially designed electric cable systems;

pressurised hollow tubing which fails at a specified temperature, the resultant
pressure drop initiating an alarm and/or extinguishant release, whereby effective
tubing systems include:

pneumatic plastic tubing, supplied from the instrument air system, specially
selected for resistance to strong sunlight, with a typical operating pressure of
43.5 psig (300 kPa) and pressure switch actuation at 36.3 psig (250 kPg);
metal tubing fitted with eutectic plugs and pressurised by air, CO2 or other
gaseous extinguishing agent.

PRESSURISATION WITH WATER FROM THE FIREMAINS SHALL NOT

BE USED AS THIS IS UNRELIABLE.

Rate-of-rise detectors

This type, designed to operate when the temperature of the operating element rises at a rate
exceeding a predetermined rate (regardless of the temperature level), includes:

pneumatic (line-type) comprising small bore tubing which is terminated in a unit set to
actuate at a predetermined pressure, the system being sealed except for calibrated vents
which compensate for normal changes in temperature;

pneumatic (spot-type), operating on the same principle as above;

thermoelectric (spot-type), comprising a thermocouple or thermopile unit which produces

an increase in electric potential in response to an increased temperature, this potential
being monitored by associated control equipment which alarms when the potential
increases at an abnormal rate.

Rate-compensated heat detectors

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This type has a fixed temperature set point at low rates of temperature increase. However, the set
point is automatically reduced proportionally as the rate of temperature rise increases, in order to
compensate for thermal lag.

(b) Heat detector settings

Unless otherwise specified:

Fixed temperature devices in ambient open areas shall be set at 174°F (79°C) (frangible
bulb coded yellow);

Internal air-conditioned area detectors shall generally be set at 154°F (68°C) (frangible
bulb coded red);

In areas where high ceiling temperatures occur, such as kitchens and laundry rooms, the
rating shall be 199°F (93°C) (frangible bulb coded green) or 286°F (141°C) (frangible
bulb coded blue) as appropriate;

Frangible bulbs and eutectic elements shall be clearly marked (or colour coded) with their
operating temperatures;

Rate of temperature rise devices shall generally be set at 46-57°F (8-14°C) per minute.

(c) Heat detector speed of response characteristics

Heat detection generally gives the slowest indication of fire due to thermal lag. (Despite this, it is
generally the preferred method because it is usually more economical, more robust, less
complicated, less sensitive to adverse environmental conditions and initiates fewer false alarms.)

Factors affecting the response time of heat detectors and which must, therefore, be taken into
account when specifying them include:

the rate of heat output from the fire;

certain characteristics of the detection system, including:

the thermal capacity and insulation of the heat sensitive element;

the rate of heat transfer to the sensitive element;
the adjustment or 'setting' of the detector.

certain characteristics of the enclosure or area itself and the siting of the detector (in
particular the height of ceilings, the depth to which the detector projects below the
ceiling, and the distance of the detector from the fire).

(d) General application

Heat detectors can be used effectively in most parts of most installations, except for the protection
of electrical equipment which generates too little heat or where significant spatial coverage is
required.

Since the heat generated by small fires tends to dissipate fairly rapidly, heat detectors shall
primarily be used to protect confined spaces. In unconfined spaces they shall be installed directly
over the hazardous equipment.
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Heat detection is effective on such fire risks as:

flammable gases, vapours, mists and low flash point liquids which burn fiercely with
immediate generation of heat;

hydrogen and certain alcohol fires which produce little smoke or visible radiation.

Heat detection shall be specified only if:

sufficient heat is expected to be generated in the area under consideration;

the speed of response would be sufficient to ensure that appropriate action can be taken in
good time.

Heat detectors shall be used where they provide a reliable alternative to smoke detection in
locations where the latter could give frequent false alarms (e.g. in kitchens and dusty areas).

The following types of heat detector may be specified outdoors:

line-type detectors such as pneumatic tubing, resistance wires or wires with melting point
insulation;
point-type frangible bulbs or eutectic plugs.

3.3.7 Smoke Detection

(a) Smoke detector types

The following types of smoke detector may be specified as appropriate:

Ionisation smoke detectors (spot-type)

This type has a small amount of radioactive material which ionises the air in the sensing chamber,
thus rendering it conductive and permitting a current flow through the air between two charged
electrodes. When smoke particles enter, they decrease this current flow. (Although the level of
radio-activity is extremely low, accurate records must be maintained of the distribution, storage,
and disposal of these detectors.)

Photoelectric light obscuration smoke detectors

This type contains a light source which is projected onto a photosensitive device. When present,
smoke particles partially block the light.

Photoelectric light scattering smoke detectors (spot-type)

In this type, the light rays do not normally fall onto the photosensitive device. When present,
smoke particles scatter the light onto the photosensitive device.

Resistance bridge smoke detectors (spot-type)

In the event of fire, smoke particles and moisture fall onto an electric bridge grid, this increasing
the conductance of the grid.

Gas sensing smoke detectors - semiconductor type

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This type respond to either oxidising or reducing gases contained in smoke by creating electrical
changes in the semiconductor.

Gas sensing smoke detectors - catalytic element type.

These contain a material which in itself remains unchanged but accelerates the oxidation of the
combustible gases contained in smoke, thus increasing the temperature of a heat-sensing element.

Line of sight smoke detectors

LOS detectors typically project an infra-red light beam from a transmitter to a receiver,
interference of the beam indicating the presence of smoke:

Their effectiveness depends heavily on:

the rigidity of fixing;
the lack of dust and other contaminants in the air.

These devices are to be specified only if called for in the Purchase Order/Contract.

In no case shall systems employing mirrors to direct the beam around corners be specified.

(b) Smoke detector settings

Smoke detectors shall be selected on the basis of the expected particle size from potential fires in
accordance with the manufacturer's advice.

(c) Smoke detector speed of response characteristics

Smoke detectors respond earlier to most types of fire than heat detectors.

In order to obtain optimum speed of response, appropriate account shall be taken of such factors
as:

the nature of the combustible material;

the properties of the combustion products (gaseous, particulate or both);
the size and weight of the particulate matter (e.g. the overheating of PVC insulation
produces large, heavy, slow moving particles);
air currents (from heat convection or ventilation);
rate of air change;
presence of structural features;
height and shape of the protected area.

Ionisation detectors respond most quickly to smokes containing small particles, such as those
produced by clean burning wood fires involving burning polymers.

(d) General application

Smoke detection shall be specified where it is necessary to give early warning of fires in materials
which smoulder for a period before developing flames (e.g. fires in electric cable and
accommodation furnishing and fittings).

LOS photoelectric smoke detectors are suitable for the protection of tall compartments and cable
tunnels where smouldering fires give rise to optically dense smoke. However, it must be noted that
 GENERAL ENGINEERING SPECIFICATION GES H.01
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these detectors are only suitable for detecting combustion particles which are larger than the
wavelength of the light source.

Photoelectric smoke detectors are not suitable for applications involving thermal turbulence (e.g.
in the presence of blower heaters or waste heat producers).

Variations in ambient light conditions must be allowed for by enclosing the detector in a container
screened from extraneous light or by modulating the frequency of the light source.

Smoke detectors are generally ineffective outdoors and shall not be specified unless otherwise
stated.

Duct smoke detectors which shut down the A/C system in the event of fire shall not be used as a
substitute for area protection as the smoke may not enter the ductwork if the HVAC system is shut
down.

The location of all detectors in air duct systems shall be permanently and clearly identified and
recorded.

3.3.8 Flame Detection

(a) Flame detector types

The following flame detector types may be specified as appropriate:

Infra-red flame detectors

IR sensors respond to a wide range of wave lengths. Consequently, they shall if necessary be fitted
with optical filters to narrow the response to the wavelength of interest.

The most common wavelength of interest is 43,500 Angstroms, the carbon dioxide emission band,
because burning carbonaceous material produces large amounts of carbon dioxide and the carbon
dioxide in the earth's atmosphere absorbs virtually all of the solar radiation in the 42,000 to 43,500
Angstrom range. HOWEVER, SUCH DETECTORS WILL NOT DETECT A FIRE IF THE FIRE
PRODUCES NO CO2 (i.e., if there is no carbon in the burning material).

In general IR type flame detectors shall be specified.

Ultra-violet flame detectors

As IR detectors will not respond to non-carbon flames (e.g. pure hydrogen), UV detectors shall be
specified for such applications. They typically work in the 1,850 to 2,450 Angstrom range.

Combined IR/UV detectors

Combination detectors, which respond only when both IR and UV are received, combine not only
the advantages of UV and IR detectors but also their limitations. Above all, although they reduce
spurious trips, they do not detect some fires. Consequently, combined types shall be specified only
if called for in the Purchase Order/Contract.

(b) Flame detector settings

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Manufacturers usually quote sensitivity in terms of the distance at which flames from 1 ft2
(approx. 0.1 m2) of gasoline will initiate alarm.

Radiation from other fuels (and thus the sensitivity of the detectors to other types of fire) will be
different.

(c) Flame detector speed of response characteristics

The most rapid fire detection is achieved with flame detection, albeit usually at higher cost than
with heat or flame detection.

Speed of response to a flame is a function of:

flame size;
distance from the detector;
spectral sensitivity with respect to the radiation emitted by the fire;
cleanliness of the lens.

(d) General application

Flame detectors, which give optimum coverage of large areas where flaming fires could occur,
shall be installed wherever rapid detection is required and significant flame is to be expected.
Area protection is accomplished by installing detectors with overlapping cones of view. The
conceptual design shall include a layout drawing showing detector locations and their areas of
coverage.

As flame detectors are LOS devices, care must be taken to ensure that they can always "see" the
entire protected area, and that they are not accidentally blocked by stacked material or equipment.

Major flammable gas systems need to be continuously monitored for possible fire situations.
Flame detectors shall be specified for this duty.

Flame detection shall not be specified for fires which produce little radiation (e.g. burning
alcohol).

IR detectors do not respond to and shall not be specified for non-carbon flames, such as:
hydrogen and hydrogen sulphide (unless mixed with a gas which contains carbon).

UV detectors are less effective in areas where fire could give off significant amounts of smoke and
shall not generally be specified for such applications..

3.3.9 Definition of Hazard Levels

(a) General

On any installation, it is essential to specify:

the various levels of hazard which may exist when operations go outside normal
parameters;
the various methods of informing people of such hazards;
the various types of automatic executive action to be provided to protect against the
possible hazards.
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With this in mind, hazard levels fall broadly into the following categories:
process upset (not covered by this specification);
fire and/or gas "Alert";
fire and/or gas "Danger";
"All Clear".

(b) "Alert" level hazards

An "Alert" level hazard is reached when the situation:

is outside normal operating parameters;

could indicate a developing fire or gas emergency but is not yet a "Danger" level hazard.

Such a situation may be identified by:

one detector of a group of detectors signalling a hazard;

one detector with two set levels signalling that the lower indication level has been
reached.

In both cases, there is a higher level of hazard to come before the situation could cause losses.

As it is possible that a single detector indicates an abnormal situation when there is in fact no
abnormal situation, generally "Alert" signals shall alarm locally and in the Control Room.
They shall NOT initiate:
"General Alarm";
major shut down;
automatic fire extinguishant release.

(c) "Danger" level hazards

A "Danger" level hazard is reached when there is confirmed gas release or fire, so that the chance
of losses is imminent.

Such a situation may be identified by:

coincident indication by two detectors in the same group (both at the higher level if the
detectors have two set levels);
a single detector in a non-voting system;
activation of an MAC.

"Danger" signals shall generally initiate:

"General Alarm";
local and Control Room alarm;
equipment shut-down;
automatic release of fire extinguishing agent.

(d) "All Clear"

The "All Clear" level is that which exists after an "Alert" or "Danger" level has reverted to normal.
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3.3.10 Required Alarm Equipment

(a) General

The alarm equipment required to operate in the event of a hazard level being identified is:

visual (steady or flashing colour-coded lights) and/or audible (sound signals or public
address).

Alarm equipment shall be provided to give warning of the potential hazard:

at the hazard location;

at a safe manned location, where the hazard type and location shall be clearly indicated
with sufficient accuracy to allow appropriate emergency response.

(b) In the field

Alarm equipment in the field shall primarily give audible signals.

However, where audible signals are unreliable or are not the quickest way to give the necessary
warning, permanently-installed equipment which gives visual signals shall be provided in addition.
These will typically be located:

in noisy or congested working areas;

at the entrance to hazardous enclosures;
at the entrance gate of unmanned facilities.

"General Alarm"

Unless otherwise specified field alarm equipment shall be capable of generating a "General
Alarm" of the following form:
audible: 1.4 sec. ramp, sawtooth wave (i.e. slow increasing, fast reducing) at
700 to 1100 Hz.
visual (if required): flashing red lamps.

"All Clear"

Audible field alarm equipment shall also be provided, capable of generating a site-wide "All
Clear" signal, which is clearly different from the "General Alarm" (e.g. a continuous sound at a
fixed frequency).

Local alarms shall have no local reset feature.

(c) In the Control Room

Detection and alarm system information shall be centralised in the Control Room, with selected
detail relayed to the Fire Station.

A control panel shall provide the Control Room operator with:

a continuous display of the status of all automatic gas and fire detection and control
systems;
the type and location of any hazard arising.
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The system may take the form of discrete lamps on a graphic panel or a VDU.
In either case the system shall:
present the information on an approximate geographical layout of the installation;
keep historic records of alarms received and actions initiated.

Items for display shall typically include:

toxic gas;
flammable gas;
fire;
extinguishing system status;
ESDs activated;
MACs activated.

Operating information which needs to be continuously displayed (e.g. that a monitoring system is
working normally) shall be steady visual.

All levels of hazard and all identified fire and gas system faults shall annunciate visually (flashing)
and audibly.

The "Danger" level relay shall be of the latching type which requires a manual reset operation.

Means shall be provided which will permit personnel to cancel the audible warnings. However, it
shall not be possible to cancel visual warnings until the condition giving rise to the alarm has
returned to normal.

"Danger" level hazard indications shall automatically initiate a "General Alarm".

The start-up of all fixed fire-fighting systems shall annunciate on the panel, whether initiated
manually or automatically.

Failure of the ventilation of any force-ventilated enclosure shall alarm on the panel (e.g. turbine
hoods and battery rooms where hydrogen may be released).

(d) In the fire station

A repeater panel, giving less detail than that available in the Control Room but still providing an
adequate overview, shall be specified for installation in the Fire Station.

(e) Signal inhibition

Inhibition key switches (for use during maintenance and testing) shall be provided for each type of
detector in each protected area on the main Fire and Gas control panel. They shall be designed to
inhibit all outgoing alarms and all automatic executive control actions from fire and gas detectors
in the inhibited area.

Keys shall be locked in the switch when in the 'inhibit' position. In this position, the key-switch
shall be illuminated. Should a detector in an inhibited area go into hazard indication mode, this
shall annunciate on the control panel and allow the operator to select the 'Auto' key position for
automatic-executive control action if required.

Where inhibit and extinguishant-release functions are contained in a common switch, the switch
shall be of the "two-action" design to prevent spurious release.

3.3.11 Required Response to Fire and Gas Detection

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(a) General

The required response to fire or gas detection is to:

warn site personnel;
contain the incident;
revert to normal conditions in a safe manner with minimum accidental loss.

Although the actions required to achieve the above will vary from case to case, the following shall
be specified as a minimum unless otherwise stated. These minimum requirements will not always
be sufficient.

(b) Response to gas alarms

Toxic gas

Unless otherwise specified, "Alert" level toxic gas indication shall initiate:
Control Room alarm.

Unless otherwise specified, "Danger" level toxic gas indication shall initiate:
Control Room alarm (if not already initiated) and
"General Alarm".

In all installations with toxic hazards, the "General Alarm" shall mean:
EVACUATE IMMEDIATELY USING BREATHING APPARATUS.

For all buildings and enclosures in or near hazardous areas and for all unmanned industrial
facilities, a flashing beacon shall be located at the entrance. Its operation shall mean "ENTER
WITH CARE".

Flammable gas

Unless otherwise specified, "Alert" level flammable gas indication shall initiate:
Control Room alarm.

Unless otherwise specified, "Danger" level flammable indication gas shall initiate the following
executive action:
Control Room alarm (if not already initiated);
General Alarm;
equipment trip;
isolate ignition sources (as far as possible);
shut in gas sources;
blow down all hydrocarbon vessels, equipment and piping within the area.

In order to minimise the risk of explosion damage, it may be necessary (depending on such factors
as layout, segregation, and valving) for the whole installation to shut down and blow down.

(c) Response to fire alarms

Unless otherwise specified, "Alert" level fire indication shall initiate:

Control Room alarm.

Unless otherwise specified, "Danger" level fire indication shall initiate:

Control Room alarm (if not already initiated);
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"General Alarm";
equipment trip;
shut in gas sources;
automatic fire extinguishant release (where provided).

Depending on circumstances, "Danger" level fire indication may also be required to initiate:
shutdown of the entire installation;
blowdown of part or all of the installation;
start of fire pump.

(d) Response to manual alarms

Activation of a manual alarm callpoint shall be taken as "Danger" level.

(e) Initiating the "All Clear"

Following any alarm condition, the "ALL CLEAR" shall be given by the Field Supervisor (or his
nominated deputy) only.

3.3.12 Cause and Effect Charts

Detection systems required to CAUSE a specified EFFECT shall be tabulated on CAUSE & EFFECT
charts where this gives a better overview of these requirements than verbal descriptions. For example, the
requirements of Section 3.3.11 (b) and (c) above may be charted.

3.4 Specific Applications

3.4.1 Open Production Areas

Open areas may be divided into two categories as follows:

(a) Large areas containing few items of equipment in them (e.g. tank farms)

Unless otherwise specified, these shall not be monitored by automatic fire and gas detection
systems (though individual equipment items in such areas may well have their own systems).

MACs shall be provided (typically at 80-120 m spacing).

(b) Congested process areas

These shall be monitored by voting flame detection systems.

Where ingress of gas could enter instrument air intakes, gas detection shall be provided.

MACs shall be provided (typically at 50-80 m spacing).

3.4.2 Force-Ventilated Hooded Hydrocarbon Equipment

(a) General

When hydrocarbon equipment is hooded (usually for noise control), provision of the hoods:
has the advantage that any fire within the hood is contained, readily detected and easily
extinguished;
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the disadvantage that any heat generated by the equipment has to be dissipated by forced
ventilation, a disadvantage because this makes the detection of any gas leaks particularly
difficult (see paragraph (c) below).

Another characteristic of such hooded systems is that, in view of the large air flows into the
enclosures (for combustion and cooling), it is common practice to provide dampers. These are
required to close in the event of emergencies (to contain fire, stop the flow of air to the fire and
contain any extinguishing agent - if it is of a gaseous type).

Although the design of dampers and their controls is outside the scope of this specification, it is a
requirement of this specification that if dampers are fitted, they shall close automatically in the
event of fan failure, fire or gas detection or ESD. Manual override facilities shall be incorporated.

In addition, a position switch shall indicate to the Fire and Gas System remotely when any damper
closes.

(b) Without gas present

For hooded systems in which there is no gas present, the following fire detection shall be
provided:

a minimum of three IR flame detectors and one rate-of-rise heat detector.

"Alert" level is given by the activation of:

one flame detector;
the rate-of-rise heat detector;
"Alert" level shall initiate:
local alarm (at the hooded equipment);
Control Room alarm;
equipment trip;
inhibit equipment start;
stop air intake fans;
close dampers.

"Danger" level is given by the activation of:

two flame detectors;
one flame detector and the rate-of-rise heat detector.

"Danger" level shall initiate:

local alarm (at the hooded equipment);
General Alarm;
Control Room alarm;
equipment trip;
inhibit equipment start;
shut off fuel intake;
stop air intake fans;
close dampers;
release extinguishing agent.

(c) With gas present

In addition to the requirements given in (a) and (b) above, the following shall apply to systems
where there is a potential source of gas release within the enclosure.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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1. Ventilation
If practicable, air flows shall be sufficiently high to ensure that plausible leaks will be
sufficiently diluted to ensure that LEL cannot be reached.

2. Gas detection
Systems shall be divided into high and low air flow systems so that the following criteria
can be applied. This subdivision shall be done in co-operation with the manufacturer of
the gas detectors.

For high air flows:

An air-powered aspirating system (vacuum pump) shall be provided to direct an

air sample to three gas detectors mounted outside the enclosure;

The aspirating system air supply shall be obtained from a reliable source;

No pump or other means of forced air movement shall be required for normal
operation.

For low air flows:

Three gas detectors shall be installed at the ventilation outlet;

Where the air is exhausted at a number of points from one area through common
ducting, gas detectors shall be positioned at the common airflow point within, or
at the outlet of, the ducting;

Where the air from an enclosure with an internal gas source is exhausted via
louvres positioned on outside walls, the gas detectors shall be positioned inside
the module adjacent to the louvres.

In addition to the requirements given in paragraph (b) previously:

"Alert" level is given by the activation of one gas detector which shall initiate:
local alarm (at the hooded equipment);
Control Room alarm;
equipment trip;
inhibit equipment start;
stop air intake fans;
close dampers.

"Danger" level is given by the activation of two gas detectors which shall
initiate:
General Alarm;
Control Room alarm;
equipment trip;
inhibit equipment start;
shut off fuel intake;
stop air intake fans;
close dampers;
release extinguishing agent.

3.4.3 Unhooded Hydrocarbon Equipment

 GENERAL ENGINEERING SPECIFICATION GES H.01
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Unhooded equipment shall generally be monitored by heat detection (usually line-type) mounted directly
above the equipment.

If provided, automatic fire-fighting systems shall interface appropriately with the detection and alarm
system.

Flame detection may also be considered.

3.4.4 Floating Roof Tanks

Floating roof tanks, in which fire can occur in the annular space between shell and floating roof, shall be
fitted with linear heat detection systems.

These may be pneumatic systems manufactured from:

metal tubing (typically copper alloy), fitted with eutectic plugs;

plastic tubing (specially chosen to be resistant to the aggressive hydrocarbon environment and
strong sunlight),;

pressurised with air, CO2 or an extinguishing gas

BUT NOT WITH WATER FROM THE FIREMAIN SINCE ITS PRESSURE IS NOT RELIABLE
ENOUGH ON A TANK FARM;

electrical systems (preferred since these can readily offer fault checking and voting).

3.4.5 Fixed Roof Tanks

Unless otherwise stated, no gas or fire detectors shall be installed on fixed roof tanks.

3.4.6 Wellheads

(a) Sweet

Wellhead areas shall be monitored by robust heat detectors (e.g. eutectic plug in steel pipe) and
flammable gas detectors installed in points of potential gas accumulation.

(b) Sour

In addition to the requirements given above for sweet wellheads, sour wellheads shall have a fixed
system to continuously monitor H2S as per API RP 55-81. The fixed sensors shall be collectively
monitored at a central point and shall be frequently tested.

3.4.7 Buildings

(a) General

Where required, detection and alarm systems for buildings shall be designed in accordance with
NFPA 72E unless otherwise specified.

In addition, buildings located where toxic or flammable gas could ingress shall have:

positive pressure air systems (typically 0.1 to 0.2 inches WG), with loss of pressure giving alarm
and appropriate gas detection at air inlets, with confirmed detection giving:

A/C shutdown;
 GENERAL ENGINEERING SPECIFICATION GES H.01
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local and Control Room alarm.

(b) Multi-storey buildings

All buildings of two or more storeys shall be fitted on all floors with automatic fire detection and
alarm systems, the principal purpose being to quickly alarm and evacuate the building. In general,
smoke detection in corridors will suffice.

The need to transmit an alarm signal to some other manned location shall be considered on a case
by case basis.

Special rooms may require special considerations as follows:

kitchens will require heat detection;
computer rooms will require dedicated smoke detection.

(c) Normally manned small buildings

Fire Station

No gas or fire detectors shall be installed as:

there are no hydrocarbons or bulk flammables present and hence no hot fires expected;
the building is largely of open construction where smoke detection would be unreliable,
the station is manned at all times;
risks are low.

Kitchens

Voting rate-compensated heat detectors shall be provided to initiate:

local and Control Room alarm;

shut down ventilation;
release extinguishing agent.

Manual extinguishant release shall also be provided.

Sleeping quarters

As a minimum, each room shall be fitted with a single, stand-alone, battery-operated smoke
detector with built-in alarm.

These detectors shall continuously indicate that they are working (usually by a small red
lamp),sound an audible alarm when the battery is running low.

Medical Clinics

These shall be provided with smoke detectors which alarm in the room and in a nearby,
continuously-manned location.

Consideration may be given to the smoke detection being of a voting design.

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Laundries

Voting rate-of-rise heat detectors/ smoke detectors (possibly combined) shall be provided to
initiate:
local and Control Room alarm;
shut down ventilation;
release extinguishing agent.

Laboratories

Failure of the ventilation system shall initiate local alarm.

Voting smoke detection shall initiate:

local and Control Room alarm;
shut down ventilation.

(d) Normally unmanned small buildings

Simple, one storey onshore buildings with low occupancy and no valuable assets will not, in
general, require automatic fire detection systems. To compensate for this, however, particular
attention shall be paid to:

the need for rapid escape from all parts of the building;
the need to minimise flammable materials stored there.

(e) Electrical buildings/rooms

Unless otherwise specified, the following shall be monitored by voting smoke detection which,
depending on individual circumstances, may need to interface with a fixed fire extinguishing
system in the event of confirmed “Danger” level smoke:

Electrical switchrooms;
Battery rooms, which shall also be fitted with hydrogen detectors if the batteries give off
hydrogen and there is a risk of it accumulating to dangerous concentrations;
Telecommunications equipment and radio operating rooms, which may also need to
automatically switch to emergency back-up communications installed in a separate
location;
Instrument control and equipment rooms;
Computer processing rooms, input/output area, tape stores.

(f) Warehouses

For high rack storage areas detectors should be placed on the ceiling above each aisle and at
intermediate level in the racks.

Line of sight smoke detectors may be considered if the warehouse is reliably free of dust and other
air-borne particles.

Unless otherwise stated in the Purchase Order/Contract, designs shall be based on NFPA 231C.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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(g) Safe enclosures in hazardous areas

When a building or other enclosure which requires safe air has to be supplied with its air from a
potentially hazardous atmosphere, flammable gas detectors shall be fitted to monitor the air inlet.
"Alert" level detection shall initiate alarm in the Control Room. "Danger" level detection shall
initiate:

closing of dampers;
local and Control Room alarm;
electrical shutdown;
ventilation/air-conditioning system shutdown.

In situations where air from a safe area is ducted to an enclosure which is located in a hazardous
area, ventilation fans shall maintain a positive air pressure of 0.1 to 0.2 inches WG in the
enclosure. Failure of the positive pressure shall result in alarm.

3.4.8 LPG areas

The principal characteristics of a major accidental release of LPG are that:

it escapes as a liquid but quickly (though not usually instantaneously) vaporises into a large cloud
and
if ignited, it immediately develops tremendous flame and heat.

Consequently, major LPG facilities shall be provided with:

gas detection;
fire detection (flame and heat).

In the LPG areas, the exact requirements of gas, heat or flare detection shall be determined on a
project specific basis.

As a minimum, applicable standards shall be strictly adhered to (see Section 3.1.2).

3.4.9 H2S Gas Detectors

(a) When specifying sensors, all background gas which could leak into the environment
surrounding the H2S sensor shall be listed together with their expected levels. Detectors
shall be selected to give fastest practical response, with minimal cross sensitivity to other
gases which may be expected to be present.

(b) Toxic gas detectors selected shall preferably be of the point type, however multi-point
sample type system may also be acceptable subject to the Owner's approval. A minimum
of two toxic gas detectors shall be installed in any one given area.

(c) A fixed system per API RP 55-B1 Section 7 shall be arranged to continuously monitor
the sour service wellhead areas where concentrations of H2S are expected. The fixed
sensors should be collectively monitored at a central point. The system shall be tested
frequently.

(d) Examples of equipment handling hydrogen sulphide in areas other than wellheads are,
sulphur units, sour water strippers and amine units. H2S detectors shall be spaced around
the boundary of the amine units risk area with no greater than 4m spacing between
detectors.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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(e) In sulphur plants, analysers or probes shall be located as follows:

One at each thermal reactor on the operating platform;

Depending on the plot size 1 or 2 at each of the 4 edges of the battery limit;
One at the loading rack area;
One at each sulphur pit near the hatch cover.

(f) In sour water strippers, analyser or probes shall be located as follows:

One or more, as required, to monitor pumps that handle the sour water;
One at sour water sump.

(g) In other areas analysers and probes shall be located as follows:

At least one at pump or compressors handling >1000 ppm H2S;

One at a manually operated sour water draw to an open sewer (not required for a closed
system).

(h) H2S detection system shall be installed in all process buildings where combustible natural
gases, volatile hydrocarbons or liquids with an H2S concentration greater than 100 ppm
are being handled and may leak accidentally into atmosphere due to equipment
malfunction or improper maintenance. For this reason, analysers handling toxic samples
shall be contained in a separate analyser house. In the buildings with vaults or
basements, the detection head shall be installed at the bottom of each unit stairway. H2S
is heavier than air and normally tends to settle. However, air movement and elevated
temperatures may cause hydrogen sulphide to rise.

(i) In sour gas plant applications, positive air pressure of 0.1 to 0.2 inches WG shall be
maintained in the control rooms, irrespective of the location of the control room. Failure
of the positive pressure shall result in an alarm. Toxic gas detectors shall be installed at
the inlet to the ventilation system serving manned locations, outside the control room
doors, inside metering and analyser shelters and houses.

(j) Toxic gas detectors shall initiate HVAC control and emergency shut down. The
executive actions (voting and final control) shall be approved by the Owner.

(k) Alarm and trip limits for the toxic detectors shall be subject to approval by the Owner.
Provisionally, for H2S these may be taken as 6ppm for alarm and 15 ppm for emergency
shutdown action, trips and actuation of the relevant building exhaust fan.

(l) H2S warning devices such as horns and flashing beacons shall be located such that these
are easily seen and heard by people both within the area as well as those people entering
the area. In noisy buildings an easily visible red rotating or strobe light shall be provided
to supplement the audible alarm system. For the case of buildings or enclosures, a
flashing beacon shall be located outside the building door. For unmanned facilities one
red rotating, blinking or strobing beacon at the entrance gate for equipment fault alarm
shall be provided.

(m) All alarms shall be acknowledged only in the control room or at the detector site of
unmanned locations only. No local reset feature shall be allowed for manned locations.

(n) The high (or critical) alarm relay shall be of the latching type which requires a manual
reset operation.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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(o) Hydrogen sulphide sensors shall not be used in lieu of flammable gas sensors e.g. to infer
the presence of a combustible vapour for the purpose of shutting down potential ignition
sources.

4.0 MATERIALS

As flammable gas detectors are poisoned by silicon, even at very low levels, extreme care shall be taken
throughout the design and specification to eliminate all possible sources of silicon. The subsequent
introduction of silicon onto the site, and the way in which it is used, shall then be strictly controlled.

5.0 SYSTEM RELIABILITY

5.1 General

(a) General Considerations

To ensure optimum reliability, system design shall take into account the specific nature of the
plant involved. The design shall be safe and meet internationally-recognised standards.

All systems shall be certified suitable for zone 1 operation (if technically possible) and for the
environmental conditions which may prevail during any emergency.

Detection systems which are subject to spurious trips shall be used either:

on a single operation basis for alarm purposes only;

on a coincident operation basis for alarm and automatic executive action.

All detectors shall have red warning label installed adjacent to these with the legend DO NOT
PAINT.

(b) Maintenance and Testing

Designs shall be such that periodic maintenance checks of all protection systems can be carried
out, covering not only the components (which must be easily accessible) but also the complete
system, including executive actions.

As far as practicable, testing shall be possible without taking the whole system out of service or
unnecessarily shutting down processes.

Systems shall be designed such that subsequent system tests can, as far as possible, simulate the
type of incident which could arise, and reflect the design intent. Component manufacturers’
recommendations shall be followed as a minimum.

(c) Environmental factors

Local environmental conditions shall be taken into account, particular attention being paid to the
potentially detrimental effects of vibration, moisture, wind and other air movement, salt- and dust-
laden air and sunlight. For example, detectors installed to monitor ventilated enclosures shall be
selected and placed so that they are effective, regardless of the operating state (on or off) of the
ventilation system.
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In areas subject to prevailing wind patterns, locations shall take appropriate account of the fact
that wind will sometimes come from other directions.

All detection and alarm equipment shall be:

of rugged construction, suitable for industrial environments, protected from mechanical damage
and adequately supported;

Sensors shall be placed on relatively vibration-free fixtures and, where appropriate, protected by a
guard to prevent mechanical damage;

Locations where it is possible for liquids to cascade over sensor shall be avoided.

All cabling and/or piping associated with protection shall be suitably protected and routed to
minimise the possibility of damage.

(d) Power supply

All fire and gas detection and control equipment shall be DC powered via dual supplies, one of
which shall be a dedicated battery/charger system. If the normal AC power supply is fed from a
non-vital source then it shall be taken from an emergency generator switchboard. Unless otherwise
specified, the back-up battery capacity shall not be less than 1½ hours at maximum load.

All electrical detector and alarm circuits shall be monitored continuously for open circuit faults,
with fault annunciation at the main annunciator panels.

In general, trip circuits (e.g. solenoid valves) shall be normally energised or fully monitored.
However, for extinguishant release, circuits shall be normally de-energised but fully monitored.

(e) Spare capacity

The spare capacity of fire and gas detection equipment, power supplies and control equipment
panels shall be sufficient for all anticipated expansion to the installation plus ten percent.

(f) Approvals

Only components which are approved as having been designed and constructed to nationally or
internationally accepted standards shall be used. Such approvals are to be issued by nationally
approved bodies.

5.2 Gas Detector Reliability

5.2.1 Toxic gas detectors

When specifying semiconductor and electrochemical H2S detectors, account shall be taken of the fact that
both types can show cross-sensitivity with other.

Typical background gases together with their effects are listed below:

Background Gas Effect

Methyl mercaptan, chlorine, hydrogen Cause high H2S reading

Sulphur dioxide, ammonia Cause low H2S reading
Lead, halogen, sulphur Render sensor inactive
 GENERAL ENGINEERING SPECIFICATION GES H.01
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Silicon vapour, glycol, oils, dirt Coat sensor, thus giving low H2S reading

For specific detectors under consideration, full details shall be obtained from the manufacturer before
detector selection is finalised.

5.2.2 Flammable gas detectors

Important reliability characteristics of the pellistor type flammable gas detector are:
the need for oxygen (enrichment or depletion of ambient oxygen levels or high humidity will change
calibration), and
the possible poisoning of the catalyst by impurities in the surrounding atmosphere (typical contaminants
being silicon vapours, lead alkyl vapours, H2S and salt spray, whilst Halons -if still in use - will temporarily
inhibit the reaction).

To minimise the risk of them being poisoned, pellistor type detectors shall not be installed until all painting
in the vicinity of the detector is completely dried out and all welding and cleaning operations have been
completed.

5.3 Fire Detector Reliability

5.3.1 Heat detectors

Frangible bulbs must not be painted or otherwise coated as this will affect the temperature at which the bulb
will actuate.

Pneumatic tubing system design shall contain safeguards against inadvertent loss of pressure due to causes
other than fire, (e.g. mechanical damage and ageing).

5.3.2 Smoke detectors

All forms of smoke detector are liable to give false alarms due to emissions resulting from normal
operations, (e.g. dust, smoke, vehicle exhausts, etc.) False alarms shall, therefore, be minimised by
including reference detectors calibrated for "normal" conditions.

The possible detrimental effects of high ambient humidity shall be evaluated when assessing the suitability
of specific smoke detector models, particularly ionisation-type detectors.

Remotely mounted smoke detector sampling line shall be identified by a label with the legend SMOKE
DETECTOR SAMPLING LINE - DO NOT DISTURB.

5.3.3 Flame detectors

To reduce susceptibility to false alarms caused by the speed of reaction, flame detectors shall be used which
require the fire signal to be present for a minimum predetermined period of time (e.g. 3 seconds).

Unlike smoke detectors (and to a lesser extent heat detectors), flame detectors are not affected by wind.

5.3.4 IR detectors

IR detectors are practically not affected by smoke or oil vapours, do not respond to arc welding or ionising
radiation, (e.g. non-destructive testing), and are less affected by dirt on the lens than UV detectors.
However:
 GENERAL ENGINEERING SPECIFICATION GES H.01
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IR detectors can be obscured by fog or heavy rain;

IR detectors respond to reflected radiation from open flames (e.g. flares);
Particular care has to be taken when selecting IR detectors for areas with high operating temperatures, (e.g.
under hoods);
The manufacturer's advice shall be specifically sought in such applications.

5.3.5 UV detectors

UV radiation is strongly absorbed by smoke and to some extent by various vapours.

UV detectors can pick up:

electric arc welding at long distances (even by reflection);

ionising radiation (e.g. non-destructive testing);
reflected radiation from open flames (e.g. reflection on the sea surface of flares).

UV detection system operation and cone of vision can be tested with a UV torch. However, because of the
high intensity of such torches, this device cannot be used for checking lens obscuration. Regular lens
cleaning is required (e.g. weekly).

UV detectors are highly susceptible to optical obscuration of the lens (e.g. dirt, salt, oil mist). They can be
provided with lens-checking devices (manually or automatically activated), which produce a fault signal
when a certain threshold of obscuration has been reached. The detector sensitivity at this point, however, is
unacceptably reduced for many fire protection applications.

6.0 INSTALLATION

(a) Vibrations such as those encountered near the heavy rotating machinery can shorten detector life.
Hence detector should be located away from such areas.

(b) Installation shall permit unhampered access for maintenance, calibration and repair.

(c) Unless calibration is one man affair, consideration shall be given to the use of telephone jacks at
the detector and the amplifier end in the control room to facilitate periodic testing.

(d) For equipment located in areas where high temperature, high humidity, corrosive and dusty
conditions are a problem, gold plated edge connectors, hermetically sealed relays and coated
printed circuit boards shall be specified for high reliability.

7.0 INSPECTION

7.1 Procedures

The inspection requirements will be covered by the document "General Conditions of Purchase" which
forms part of the Purchase Order/Contract. Additional requirements are given below.

The Vendor/Contractor shall provide the Inspector with the names of all Sub-Vendors/Sub-Contractors.

The Vendor/Contractor always has the responsibility to provide adequate quality control and inspection.
Any inspection by Owner or his Inspector shall not relieve the Vendor/Contractor of these responsibilities
or those under his guarantees.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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The Inspector shall ensure that any shortcomings in the Vendor/Contractor's documentation or data are
rectified before any equipment or material is accepted for shipment.

8.0 TESTING

8.1 Statutory Tests

8.1.1 All completed detection and alarm systems shall be performance tested to ensure that they are capable of
giving the performance specified.

8.1.2 All testing shall be carried out in the presence of the Owner's Inspector.

8.1.3 After installation a visual inspection of all detectors shall be made to ensure that they are properly located
and secured. Each detector shall be checked to ensure that it is properly connected and powered in
accordance with the manufacturer's recommendations.

8.1.4 Unless otherwise stated, all tests recommended by the manufacturer shall be performed.

8.1.5 All detectors, alarms and shutdown logic shall be fully tested during commissioning using the relevant test
gas or medium or UV/IR lamp which simulates the hazard reasonably accurately.

8.1.5 The results of tests shall be included in the handover documents.

8.2 Test Procedures

8.2.1 The Vendor/Contractor shall approve all test procedures to ensure that all equipment is adequately checked
to ensure that it is correctly installed and functioning as intended.

8.2.2 Any method or device used for testing in a hazardous atmosphere shall be suitable for use within that
atmosphere.

8.2.3 A permanent record shall be kept of all tests.

8.2.4 The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval prior to the
start of the testing programme.

8.3 Test Certificates

8.3.1 Final acceptance of the system will be given following satisfactory Final Acceptance Tests.

All copies of test certificates shall be furnished with final drawings as called for in the documentation
section. The Final Acceptance Tests shall be witnessed by the Inspector who shall retain one copy of the
certified tests.

Information included on test certificates shall include:

manufacture;
model number;
date of manufacture;
approvals;
number and type of detectors per zone for each zone;
all tests recommended by the manufacturer;
tests performed;
 GENERAL ENGINEERING SPECIFICATION GES H.01
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test results including, as applicable, such parameters as pressures, temperatures, electrical

resistance;
corrective action taken;
signature of tester;
date of testing.

8.4 Site Acceptance Test Requirements

8.4.1 General

The Vendor/Contractor shall provide all consumables and personnel for the specified performance testing.

During commissioning tests, all persons who would automatically receive an alarm shall be notified, so that
they do not make unnecessary response.

Non-restorable detectors shall be tested mechanically and/or electrically without damaging the detector.

Unless calibration is one man affair, consideration shall be given to the use of telephone jacks at the
detector and the amplifier end in the Control Room to facilitate periodic testing.

8.4.2 Heat detectors

Restorable heat detectors shall be tested with a heat source (e.g. hot air or shielded lamp device) until they
respond. After each test, the detector shall reset.

Electrical line-type heat detectors shall have their loop resistance measured to check that it is within
required limits. The test result shall be recorded for future reference.

Where eutectic elements are used to hold moving parts in position (e.g. dampers), they shall be removed to
check that the moving parts function correctly.

8.4.3 Smoke detectors

Detector sensitivity shall be determined using a calibration method recommended by the detector
manufacturer.

Detectors shall not be tested using a spray device that administers an unmeasured concentration of aerosol
into the detector.

Smoke detection systems shall be tested with ventilation/air-conditioning in operation and the test smoke
source at floor level and at various potential smoky fire locations. This will ensure not only that the
components are in order but also that the response time is acceptable.

Air duct detector testing shall:

be done with and without enclosure ventilation fans running;

include testing of any seals which are necessary for the system to function correctly.

8.4.4 Flame detectors

Flame detectors shall be tested using wavelengths expected to be emitted during an actual fire situation.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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8.5 Test Equipment

8.5.1 Supply

All necessary test accessories shall be provided.

Note:

All instrument and apparatus used in the performance of the tests shall have been calibrated to an agreed
standard at a laboratory of National standing within a period of fifteen (15) months of the test date. The
cost of carrying out such calibrations shall be borne by the Vendor/Contractor in all cases.

9.0 DOCUMENTATION

9.1 Introduction

9.1.1 This section covers the documentation required for the conceptual design, testing for all the equipment,
components and services to be provided against this specification.

9.1.2 The detailed list of documents that are required is included with the Purchase Order/Contract.

9.1.3 The documents as listed may be considered as a minimum requirement; all details to confirm compliance
with the relevant specifications, and to allow a full and continued appraisal to be made of the
Vendor/Contractor's proposals and interpretations of the ordered equipment, should be submitted in
accordance with the schedule specified in the Purchase Order/Contract.

9.1.4 Any production or procurement undertaken by the Vendor/Contractor which is prior to the relevant
documentation being submitted and reviewed by the Owner is at the Vendor/Contractor's risk.

9.1.5 On all documentation, the Purchase Order/Contract number, equipment title, tag number and project name
shall be quoted.

9.1.6 All documentation shall be checked and signed by the checker before submission.

9.1.7 All equipment, components and services provided against this specification shall be fully documented and
any changes to any document shall be recorded by changing the document index.

9.1.8 During the course of the purchase, the Vendor/Contractor shall supply the following documents:

overall conceptual design;

drawings as per Section 9.4;
details of the detection, control and alarm provisions to be made for each risk;
a clear statement of risks not covered;
Cause & Effect charts as appropriate;
standardised audible and visual alarm signal details.
Interfaces with:
existing systems;
other new alarm systems not within the Vendor/Contractor's scope of supply, automatic fire
extinguishing systems.

9.2 Schedules and Reports

9.2.1 The Vendor/Contractor shall submit with his tender a preliminary quality control plan.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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9.2.2 The Vendor/Contractor shall include with his tender documentation a statement of proposed sub-vendors, a
document submission schedule for all documents based on a review cycle of three weeks and outline
programme for procurement and production activities.

9.2.3 The Vendor/Contractor shall incorporate any revisions agreed with the Owner during the enquiry review
stage.

9.2.4 Monthly reports shall be submitted by the Vendor/Contractor detailing conceptual design and
documentation activities, the format of which shall be agreed with the Owner.

9.3 Data and Calculations

Not applicable.

9.4 Drawings

9.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
and/or the Inspection Authority.

9.4.2 General arrangement drawings shall be to scale and show the relevant location and main dimensions of all
components, including elevations and orientations.

9.4.3 As-built drawings may be the general arrangement drawings marked-up with the actual as-built
dimensions.

9.4.4 General arrangement drawings shall be supplied showing:

detector locations and areas of coverage;

control panel locations;
alarm sounder locations and areas of coverage.

9.5 Final Records, Documents and Manuals

9.5.1 Two copies of the Data Dossier shall be supplied and shall be a record of the conceptual design process.

Where stated in the Purchase Order/Contract, it shall contain the following:

general arrangement drawing and bill of material;
the quality control plan;
hazardous area drawings;
non-conformity records;
approvals by the Independent Inspection Authority;
certificate of conformity;
Owner's release certificate.

As a minimum, the Data Dossier shall contain:

the overall conceptual design;
general arrangement drawings;
Cause & Effect charts;
standardised audible and visual alarm signal details.

Interfaces with:
existing systems;
other new alarm systems not within the Vendor/Contractor's scope of supply;
automatic fire extinguishing systems.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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9.5.2 Six sets of the Installation, Operations and Maintenance Manual (IOM) shall be specifically compiled for
the equipment supplied. A compendium of manufacturer's data for a range of like products is not
acceptable. The IOM shall contain the following:

- a description of the equipment;

- the master document list and certified copies of key drawings;
- packing, shipping and site preservation instructions;
- step by step installation instructions;
- step by step pre-commissioning procedures;
- step by step commissioning procedures;
- step by step procedures for dismantling and re-assembly;
- routine preventive maintenance schedule and major repair procedures;
- list of special tools;
- spare parts ordering information.

The IOMs shall be presented in A4 format, and be securely bound in heavy duty 4-ring binders.

9.5.3 The Vendor/Contractor shall produce as-built documents revised to indicate field changes.

9.5.4 The Vendor/Contractor shall supply one set of mylar original drawings.

9.5.5 Electronic Data Format (EDF)

All documentation (drawings, calculations and Data Sheets etc) shall be produced by the
Vendor/Contractor in electronic format.

The format shall be compatible with that used by the Owner and shall be agreed at the commencement of
the contract.

In addition to the 'hard copies' required under the contract, copies of the electronic records shall be issued
to the Owner for all approved documentation, this forming part of the Vendor/Contractor's contractual
obligations.

10.0 PRIOR TO SHIPMENT

10.1 Painting and Coatings

Where relevant all bare surfaces which are exposed during transit or storage shall be given a coat of
temporary rust inhibiting material.

10.2 Spares

The Vendor/Contractor shall submit with his proposal a priced list of recommended spares for start-up and
two years operation for review by the Owner. This list shall include, but not be limited to:

- special tools, if required;

- limited shelf-life equipment replacements.

10.3 Packing and Storage

This section describes the minimum requirements for the preservation and protection of equipment during
the sea and land transportation and storage prior to installation.
 GENERAL ENGINEERING SPECIFICATION GES H.01
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The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24
months shall be assumed. Packing to be suitable for sea freight.

(a) After mechanical completion at the works, the equipment shall be left in a clean dry condition.

(b) The Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent
damage during shipment.

The Vendor/Contractor shall submit his procedures for packing and preservation for review by the Owner.

10.4 Shipping

Detailed shipping arrangements are covered by the Purchase Order/Contract.

The equipment shall not leave the Vendor/Contractor's works for shipment until the release has been
approved by the Owner's Inspector.

10.5 Warranty

10.5.1 The Vendor/Contractor shall warrant all materials and services supplied against any defect, for a minimum
period of 12 months after commissioning, or 24 months from the date of delivery to the site, whichever is
the shorter period, or for the period stipulated in the Purchase Order/Contract.

10.5.2 Should any item be found defective the Vendor/Contractor shall be responsible for all costs associated with
restoring the equipment to the standard equivalent to that specified in the Purchase Order/Contract.

10.5.3 The Vendor/Contractor shall undertake to carry out the repair or replacement in an expeditious manner.The
terms and conditions of the Warranty shall be additional to any other requirements specified in the
Purchase Order/Contract.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.02

SAFETY SIGNS AND THEIR APPLICATIONS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 2 of 24
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 5

2.0 DEFINITIONS 6

2.1 Technical 6
2.2 Contractual 7

3.0 DESIGN 8

3.1 Codes and Standards 8

3.2 Universal Safety Sign Requirements 8
3.3 Signboards 9
3.4 Illuminated signs 10
3.5 Acoustic Signals 10
3.6 Verbal Communications 11

4.0 GENERAL USE OF SAFETY SIGNS 11

4.1 Organisational Requirements 11

4.2 Personnel Requirements 12
4.3 Using Safety Sign Hardware 12
4.4 Using Verbal Communications 13
4.5 Using Hand Signals 13
4.6 Hand Signal Method 13

5.0 CONTROLLING SPECIFIC HAZARDS 14

5.1 Hazardous Substances 14

5.2 Hazardous Lifting and Moving Operations 14
5.3 Fire Hazards 14
5.4 Physical Hazards 15
5.5 Vehicle Control 15

6.0 EQUIPMENT PURCHASE 15

6.1 Design and Construction 15

6.2 Inspection and Testing 15
 GENERAL ENGINEERING SPECIFICATION GES H.02
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SEC TITLE PAGE

6.3 Documentation 15
6.4 Spares 16
6.5 Packing and Shipping 16
6.6 Warranty 16

7.0 FIGURES SUB-INDEX 17

Figures 18
 GENERAL ENGINEERING SPECIFICATION GES H.02
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification defines the minimum requirements for safety signs, signals and their applications.

1.1.2 This specification applies to safety signs, signals and their applications for refineries, onshore oil and gas
installations and processing facilities.

1.1.3 This specification does not cover:

- the transport outside Company-controlled premises of dangerous goods;

- the supply and marketing of hazardous substances or equipment;
- public road markings;
- machinery operation labels;
- colour coding of fire extinguishers.

1.1.4 The provision of safety signs shall be based upon the following:

a) Safety signs shall be provided at all places of employment where there is a significant risk and it is
necessary to warn people:

- not to enter a given area unless authorised to do so;

- to enter and act with care;
- to enter only with the indicated personal protection equipment.

b) In order for the above warning messages to be quickly given and understood by all persons who
may consider entering a hazardous location, safety signs shall be:

- essentially pictorial;
- shape and colour coded;
- standardised throughout the Company so that:

- a given sign always indicates the same warning;

- a given warning is always indicated by the same sign.

c) The provision of safety signs shall be treated as the last resort to minimise risks and shall not be
considered as a substitute for:

- best possible engineering controls;

- safe working procedures;
- the provision of appropriate personal protection equipment, requirements for which shall
always be developed first.

d) Safety signs shall be provided where they can help reduce risk and shall NOT be used to simply
remind workers of safety in general. (This shall be done using safety posters which are especially
designed for that purpose.)

e) Where risks are insignificant, safety signs shall NOT be provided (as this would give an
inconsistent message).

f) When determining the need for safety signs, full consideration shall be given to the needs of:

- those who normally enter the danger area;

 GENERAL ENGINEERING SPECIFICATION GES H.02
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- fire-fighters who will need to enter in the event of fire.

g) Details of relevant British Standards have been included in this specification for possible entry
into Purchase Orders/Contracts and operating procedures as appropriate. The inclusion of this
information is not intended to be restrictive.

1.1.5 The provisions of hand signals shall be based upon the following:

a) Hand signals shall be used as directions for directing hazardous operations:

- not to enter a given area;

- to start/stop the hazardous operation;
- to indicate the end of the operation;
- to indicate the direction the operation is to proceed.

b) In order for the above hand signals to be given and fully understood by all persons involved in the
hazardous operation they shall be:

- given in a precise manner;

- simple as possible to understand;
- clear from a distance;
- easy to make and understand;
- consistent with the various movements.

c) Hand signals shall be given when the need to direct temporary hazardous operations is required.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES A.04 Noise Level Criteria and Noise Control

GES C.03 Safety Procedures on Construction Sites

GES H.10 First Aid and Medical Facilities

GES H.11 Protective Clothing and B.A sets

GES X.02 Colour Coding of Equipment and Piping

 GENERAL ENGINEERING SPECIFICATION GES H.02
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2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Safety

Within the context of this specification the term 'Safety' shall refer to a healthy and non-hazardous working
environment.

Safety sign

A sign (including all related hardware and software components) providing for instance, information and/or
instruction about safety at work by means of:

- a coloured signboard;
- an illuminated sign;
- an acoustic signal;
- a verbal communication;
- a hand signal.

Signboard

A sign which provides information or instructions by a combination of shape, colour and a symbol or
pictogram (sometimes with supplementary text) which is rendered visible by lighting of sufficient intensity.

Prohibition sign

A sign prohibiting behaviour likely to increase or cause danger (e.g. no smoking).

Warning sign

A sign giving warning of a hazard or danger (e.g. warning of electrical hazards).

Mandatory sign

A sign prescribing specific behaviour (e.g. the wearing of specific Personnel Protection Equipment).

Emergency escape or first aid sign

A sign giving information on emergency exits, first-aid or rescue facilities (e.g. safety shower, emergency
telephone).

Fire safety sign

A sign which provides for instance, information on:

- escape routes and emergency exits in case of fire;

- the identification or location of fire-fighting equipment;
- warning in case of fire.

Hazard

The potential to cause harm.

 GENERAL ENGINEERING SPECIFICATION GES H.02
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Consequence

The likely severity of harm from a particular hazard.

Frequency

The likelihood that a particular hazard will occur.

Risk

A multiple of consequence and frequency, a high risk thus incorporating a high likely severity and a high
likelihood of occurrence.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.
 GENERAL ENGINEERING SPECIFICATION GES H.02
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Rev 0 1999
33.0 DESIGN

3.1 Codes and Standards

3.1.1 The designs shall comply with this specification and the following Codes and Standards.

IEC 61310 Safety of machinery. Indication, marking and actuation.

BS 1710 Specification for identification of pipelines and services.

BS 5378 Safety Signs and Colours

Part 1: Specification for colour and design,
Part 2: Specification for colorimetric and photometric properties of materials, &
Part 3: Specification for additional signs to those given in BS 5378 : Part 1

BS 5499 Fire safety signs, notices and graphic symbols

Part 1: Specification for fire safety signs,
Part 2: Specification for self-luminous fire safety signs, &
Part 3: Specification for internally-illuminated fire safety signs.

BS 6736 Code of practice for hand signalling for use in agricultural operations.
(Although not written for the oil and gas industry, this provides useful guidance.)

BS 7121 Code of practice for safe use of cranes.

BS 7443 Specification for sound systems for emergency purposes.

BS PD 6578 Guide to British, European and international graphical symbols, for use on equipment, for
safety and fire safety.

3.1.2 Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and Standards
at the time of the order shall be used.

3.2 Universal Safety Sign Requirements

3.2.1 Safety signs shall:

- say what they mean;

- mean what they say;
- clearly define safety requirements;
- be installed in positions appropriate to the line of sight, taking account of any obstacles, in a well-
lit, visible location.

3.2.2 Safety signs which rely on an external power source to perform their function shall:

- pose no additional hazard (e.g. ignition risk in flammable atmospheres);

- remain active once activated until:
- the danger ceases;
- receipt of a planned acknowledgement.
- be provided with automatic back-up power.

3.3 Signboards

3.3.1 All safety signboards shall be designed, constructed, tested and approved to standards outlined in
 GENERAL ENGINEERING SPECIFICATION GES H.02
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Rev 0 1999
Section 3.1.

3.3.2 Signboard pictograms shall be kept as simple as possible, consistent with giving their message.

3.3.3 Where it is necessary for written text to supplement the pictorial message given by a signboard, subject to
Owner's preference, this text shall preferably be given in English and Arabic in the following manner:

English - PICTURE - Arabic

3.3.4 Supplementary text boards shall:

- have the same colour scheme as the associated pictorial message;

- reflect the same safety sign category.

3.3.5 A safety signboard shall NOT consist of only text and/or directional arrows.

3.3.6 All safety signboards shall:

- fall into one of the following categories and be shaped and colour coded as detailed below, using
phosphorescent, reflective, and/or internally or back-lit systems as appropriate.

(a) Prohibition signs:

- round shape;
- black pictogram on white background;
- red edging and red diagonal line;
- the red part to cover at least 35% of the entire sign.

See Prohibition Signs in Figure 7.1.

(b) Warning Signs:

- triangular shape;
- black pictogram on yellow background;
- black edging;
- the yellow part to cover at least 50% of the entire sign.

See Warning Signs in Figure 7.2.

(c) Mandatory Signs:

- round shape;
- white pictogram on blue background;
- white edging;
- the blue part to cover at least 50% of the entire sign.

See Mandatory Signs in Figure 7.3.

(d) Emergency escape or first-aid signs:

- rectangular or square shape;

- white pictogram on green background;
- white edging;
- the green part to cover at least 50% of the entire sign.

See Emergency Escape and First Aid Signs in Figure 7.4.

 GENERAL ENGINEERING SPECIFICATION GES H.02
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Rev 0 1999
(e) Fire-fighting signs:

- rectangular or square shape;

- white pictogram on red background;
- white edging;
- the red part to cover at least 50% of the entire sign.

See Fire-Fighting signs in Figure 7.5.

(f) Hand Signals

Hand signals used to direct hazardous operations shall be precise, simple, expansive, easy to make and
understand, clear from a distance, and CONSISTENT.

Hand signals shall use both arms at the same time, the arms moving symmetrically.

See General Hand Signals in Figure 7.6.

See Danger Hand Signals in Figure 7.7.

3.4 Illuminated Signs

3.4.1 Illuminated signs shall be used in a situation where a person may find it difficult to read or understand
during day or night time and they shall be bright enough to be seen without causing glare.

3.4.2 If a flashing illuminated sign is used indicating a higher level of danger than the continuous light, the
duration and frequency of flashing shall be in line with:

- the pulse time;

- interval of any acoustic signal used in conjunction with it.

3.4.3 If a flashing illuminated sign is used to warn of imminent danger then:

- measures shall be provided to quickly detect its failure;

- duplicated signs shall be provided.

3.5 Acoustic Signals

3.5.1 Acoustic signals shall be used in situations where signs are not visible to personnel and chosen such that
they:

- can be clearly heard above the ambient noise level at the workplace (e.g. 10 dB above the ambient
noise at that frequency);
- give no pain or excessive discomfort;
- are easily and quickly recognised.

3.5.2 Where more than one acoustic signal is used to give different safety messages, only one signal may
transmit at a time.

3.5.3 A device capable of emitting an acoustic signal at variable frequencies, or intermittently, may be specified
to indicate varying levels of danger.

3.5.4 Audible fire alarms shall be:

- audible throughout the workplace;

- easily recognisable;
- distinct from other acoustic signals and ambient noise.
 GENERAL ENGINEERING SPECIFICATION GES H.02
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3.5.5 Public address systems to supplement audible fire alarms shall be considered in locations with large
numbers of visitors.

If provided, public address systems shall:

- be used during emergencies to issue only pre-formulated, clear, concise messages (which
have possibly been pre-recorded);
- NOT hinder communication with the fire brigade.

3.5.6 The signal for evacuation shall be continuous.

3.6 Verbal Communications

3.6.1 Verbal communications used to direct hazardous operations shall be short, precise, easy to say and
understand, clear from a distance, and CONSISTENT.

3.6.2 Verbal communications shall be real words in one language.

3.6.3 Examples of verbal communications for use in directing hazardous operations:

Start Start an operation;

Stop Stop or interrupt an operation;
End Completely stop (i.e. finish);
Danger Emergency STOP;
Raise Raise a load;
Lower Lower a load;
Forwards Move forwards;
Backwards Move backwards;
Right Move to the signalman's right;
Left Move to the signalman's left;
Quickly Speed up a movement;
Slowly Slow down movement.

4.0 GENERAL USE OF SAFETY SIGNS

4.1 Organisational Requirements

4.1.1 The number, distribution and type of safety signs to be used at a given location, shall be determined on the
basis of the safety risks at that location, with particular attention to those risks presented by:

- flammable materials;
- materials hazardous to health;
- electrical systems;
- dangerous machinery;
- protruding objects;
- overhead work;
- pits, shafts and excavations;
- confined spaces;
- noise.

4.1.2 Where safety sign hardware is required, there shall be a reliable system in place for the adequate
supervision of its purchase, installation, storage, distribution, inspection, maintenance and replacement.

4.1.3 Care shall be taken to limit the number of signboards in close proximity to each other as this will only
result in confusion.
 GENERAL ENGINEERING SPECIFICATION GES H.02
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Rev 0 1999
4.1.4 If circumstances change, making a safety sign no longer valid, it shall be modified or removed as
appropriate.

4.1.5 No safety signs shall be installed, removed or modified without written authorisation.

4.1.6 Safety signs used at each location shall be re-assessed at least every 3 years, and before any significant
change in the activities at the location.

4.2 Personnel Requirements

4.2.1 Those deciding on the selection and location of safety signs at specific locations shall have been given
appropriate training.

4.2.2 Those receiving, handling and storing safety signs shall:

- have been given appropriate training;

- store the equipment as intended by its manufacturer, adequate to protect from damage and loss;
- report all items received damaged or damaged whilst in their care;
- report lost items and initiate reordering as necessary.

4.2.3 All persons working on an industrial site shall be:

- adequately instructed in the safety signs and their meanings;

- required to comply with all safety signs.

4.2.4 All workers and supervisors shall be trained in the action required of them in an emergency.

4.2.5 Any persons not adequately instructed in all of the system of safety signs in use (e.g. occasional visitors)
shall be accompanied throughout their visit to the site by a person who is adequately instructed.

4.3 Using Safety Sign Hardware

4.3.1 Permanent safety signboards shall be used for signs relating to prohibitions, warnings, mandatory
requirements and the location and identification of emergency escape routes, first-aid facilities and fire-
fighting equipment.

4.3.2 Where appropriate, more than one type of safety sign shall be provided for a given danger (e.g. a signboard
warning of the general presence of a hazard PLUS an acoustic signal which is activated if the danger
becomes acute). Typical examples include the dangers presented by stored or processed flammable or toxic
substances.

4.3.3 Safety signs which rely on an external power source to perform their function shall have increased regular
inspection and testing appropriate to their design and construction.

4.3.4 Illuminated signs shall be located so that they are not adversely affected by other lighting.

4.3.5 If the hearing or sight of workers in a given location are impaired (e.g. by the use of respiratory protection
devices) then the effectiveness of safety signs shall be increased appropriately (e.g. by increasing their size,
brilliance or volume).

4.4 Using Verbal Communications

4.4.1 When verbal communications are used, the signalman's duties shall consist exclusively of directing
manoeuvres and ensuring the safety of workers in the vicinity.

4.4.2 When verbal communications are used, the signalman and the operators to whom he is signalling shall
 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 13 of 24
Rev 0 1999
adequately understand the meaning of the words used and be able to pronounce them.

4.4.3 Loud hailers may be used provided that the words remain clear at all times.

4.4.4 Whenever possible, verbal communications shall be co-ordinated with corresponding hand signals.

4.5 Using Hand Signals

4.5.1 When hand signals are used the signalman's duties shall consist exclusively of directing manoeuvres and
ensuring the safety of workers in the vicinity.

4.5.2 Only one hand signal shall be given at a time.

4.5.3 When hand signals are to be used:

- the signalman shall be able to see all manoeuvres being made by the operators to whom he is
signalling without being endangered by them;
- the operators must be able to clearly see and recognise the signaller without difficulty.

4.5.4 If due to weather conditions visibility is poor, the work may continue if adequate visibility can be achieved
by:

- the signalman and the workers wearing high visibility clothing;

- the signalman using illuminated signalling bats and reflective arm bands;
- deploying extra signalmen.

4.5.5 If adequate visibility cannot be achieved then hand signals shall NOT be relied upon to achieve the
necessary safe control of the work.

4.6 Hand Signal Method

4.6.1 Hand signals used to direct hazardous operations shall be precise, expansive, easy to make and understand,
clear from a distance and CONSISTENT.

4.6.2 Hand signals shall use both arms at the same time, the arms moving symmetrically.

4.6.3 Examples of acceptable hand signals to be used to direct hazardous operations are shown in Section 7.0.

5.0 CONTROLLING SPECIFIC HAZARDS

5.1 Hazardous Substances

5.1.1 Where a hazardous substance is processed, appropriate warnings shall be installed:

- at points visible from walkways;

- at points where workers are most likely to come into contact with the substance (e.g. sampling
points, filling points, vents, and drains).

5.1.2 Where a significant quantity of a particular hazardous substance is stored, appropriate warning signs shall
indicate this presence. The signs shall be installed:

- so that they are visible from normal walkways;

- at all entrances to the store.

5.1.3 Where a limited quantity of a particular hazardous substance is stored and the substance is in a proper
container which is itself clearly and appropriately marked, no additional warning signs are required to
 GENERAL ENGINEERING SPECIFICATION GES H.02
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indicate its presence.

5.1.4 Stores containing a number of different hazardous substances shall have 'general danger' warning signs.

5.2 Hazardous Lifting and Moving Operations

5.2.1 Verbal communications and/or hand signals shall be used where necessary to guide persons carrying out
hazardous manoeuvres.

5.2.2 A code of verbal and hand signals to be used to direct hazardous operations shall be published and
distributed throughout the Company to those concerned, including:

- site supervisors;
- signalmen and operators required to work to signals;
- safety personnel.

5.3 Fire Hazards

5.3.1 Fire exit signs shall be installed at all emergency exits and exits which are not normally used or not
immediately obvious.

5.3.2 Fire exit signs shall be installed immediately above the exit opening or, if this is not possible, at a position
where:

- the sign can be clearly seen;

- the sign is least likely to be obstructed or obscured by smoke.

5.3.3 Where an exit cannot always be seen (e.g. from a staircase), a fire exit sign including a directional arrow
shall be installed.

5.3.4 Where there is a danger that a fire exit may become obstructed because its importance is not universally
appreciated (e.g. a seldom-used intercommunication door), conspicuous "FIRE ESCAPE - KEEP CLEAR"
signs with appropriate pictograms shall be installed on both sides of the door.

5.3.5 Fire-fighting equipment locations shall be indicated by appropriate signboards and/or painting the
background behind the equipment red.

5.3.6 If for any reason fire-fighting equipment has to be located in a position hidden from view, its location shall
be indicated by signboards with appropriate pictograms and directional arrows.

5.4 Physical Hazards

A pattern of black and yellow 45 degree stripes shall prominently identify such hazards as:

- protruding objects and structures into which a person might accidentally walk (e.g. the edge of a
raised platform, low doorways, low cantilevers), and
- locations where there is a risk of falling and it is not possible to install guard rails.

5.5 Vehicle Control

For the safe control of vehicular traffic within Company-controlled premises:

- permanent traffic routes shall be permanently marked;

- normal road traffic signs (not defined in this specification) shall be installed where necessary.

6.0 EQUIPMENT PURCHASE

 GENERAL ENGINEERING SPECIFICATION GES H.02
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6.1 Design and Construction

6.1.1 Only safety signs which comply with the Codes and Standards stated in Section 3.1.1 shall be provided.

6.1.2 All painting and coating shall be adequate for the intended service.

6.2 Inspection and Testing

6.2.1 Safety signs will usually be off-the-shelf standard items and, as such, shall be strictly controlled by the
manufacturer's quality control systems.

6.2.2 The Vendor/Contractor always has the responsibility to provide adequate Quality Control and inspection of
equipment and materials. Any inspection by Owner or his Inspector shall not relieve the Vendor/Contractor
of these responsibilities or those under his guarantees.

6.2.3 All equipment and materials shall be tested in accordance with the Vendor/Contractor's standard procedures
prior to leaving the Vendor/Contractor's factory. The results of all tests performed shall be recorded on
signed test certificates.

6.2.4 If so specified on the Purchase Order/Contract, selected testing shall be carried out in the presence of the
Owner's Inspector.

6.2.5 The Vendor/Contractor shall provide all consumables, personnel and the site, systems and equipment
required for testing.

6.2.6 The Inspector shall ensure that any shortcomings in the Vendor/Contractor's documentation or data are
rectified before any equipment is accepted for shipment.

6.3 Documentation

6.3.1 Where Installation, Operation and Maintenance Manuals (IOMs) are required, these shall be provided six-
fold in English and checked for completeness by the Inspector.

6.3.2 All equipment and materials shall be fully documented and changes to any document shall be recorded by
changing the document index.

6.3.3 Electronic Data Format (EDF)

All documentation (drawings, calculations and Data Sheets etc) shall be produced by the
Vendor/Contractor in electronic format.

The format shall be compatible with that used by the Owner and shall be agreed at the commencement of
the contract.

In addition to the 'hard copies' required under the contract, copies of the electronic records shall be issued
to the Owner for all approved documentation, this forming part of the Vendor/Contractor's contractual
obligations.

The detailed list of documents that are required is attached to the Purchase Order/Contract.

6.4 Spares

For equipment requiring spare parts, the Vendor/Contractor shall submit with his proposal a priced list of
recommended spares for two years operation for review by the Owner.

6.5 Packing and Shipping

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6.5.1 Before shipment, all equipment and materials shall be inspected for compliance with the Purchase
Order/Contract.

6.5.2 The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24 months
shall be assumed. Packing to be suitable for sea freight.

6.5.3 The following preparation for shipment shall be a minimum requirement:

- after completion at the works, all equipment supplied to this specification shall be left in a clean
dry condition;
- the Vendor/Contractor shall be responsible for packing the equipment and materials to prevent
damage during shipment.

6.5.4 Detailed shipping arrangements are covered by the Purchase Order/Contract.

6.6 Warranty

The Vendor/Contractor shall warrant all material and services supplied against any defect for a period of
twelve (12) months after commissioning, or twenty-four (24) months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.
 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 17 of 24
Rev 0 1999
7.0 FIGURES SUB-INDEX

Figure 1 Prohibition Signs 18

Figure 2 Warning Signs 19
Figure 3 Mandatory Signs 20
Figure 4 Emergency Escape and First Aid Signs 21
Figure 5 Fire-Fighting Signs 22
Figure 6 General Hand Signals 23
Figure 7 Danger Hand Signals 24
 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 18 of 24
Rev 0 1999

NO SMOKING SMOKING AND NAKED NO ACCESS FOR

FLAMES FORBIDDEN PEDESTRIANS

DO NOT EXTINGUISH NOT DRINKABLE NO ACCESS FOR

WITH WATER UNAUTHORISED PERSONS

NO ACCESS FOR DO NOT TOUCH

INDUSTRIAL VEHICLES

EXAMPLES

FIGURE 7.1 PROHIBITION SIGNS

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 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 19 of 24
Rev 0 1999

FLAMMABLE MATERIAL EXPLOSIVE MATERIAL TOXIC MATERIAL

OR
HIGH TEMPERATURE (a)

CORROSIVE MATERIAL RADIOACTIVE MATERIAL OVERHEAD LOAD

INDUSTRIAL VEHICLES DANGER: ELECTRICITY GENERAL DANGER

LASER BEAM OXIDANT MATERIAL NON-IONISING

RADIATION

EXAMPLES

(a) IN THE ABSENCE OF A SPECIFIC SIGN FOR HIGH TEMPERATURE

FIGURE 7.2 WARNING SIGNS

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 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 20 of 24
Rev 0 1999

EYE PROTECTION SAFETY HELMET EAR PROTECTION

MUST BE WORN MUST BE WORN MUST BE WORN

RESPIRATORY SAFETY BOOTS SAFETY GLOVES

EQUIPMENT MUST BE WORN MUST BE WORN
MUST BE WORN

SAFETY OVERALLS FACE PROTECTION SAFETY HARNESS

MUST BE WORN MUST BE WORN MUST BE WORN

PEDESTRIANS MUST GENERAL MANDATORY SIGN

USE THIS ROUTE (TO BE ACCOMPANIED WHERE
NECESSARY BY ANOTHER SIGN)

EXAMPLES

FIGURE 7.3 MANDATORY SIGNS

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 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 21 of 24
Rev 0 1999

FIRST-AID POINT STRETCHER SAFETY SHOWER EMERGENCY

TELEPHONE FOR
FIRST-AID OR ESCAPE

EXAMPLES

FIGURE 7.4 EMERGENCY ESCAPE OR FIRST-AID SIGNS

S:\H-SERIES\H-02\H02FigR0.XLS
 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 22 of 24
Rev 0 1999

FIRE HOSE LADDER

EMERGENCY FIRE FIRE EXTINGUISHER

TELEPHONE

SUPPLEMENTARY 'THIS WAY' SIGNS FOR FIRE-FIGHTING EQUIPMENT

EXAMPLES

FIGURE 7.5 FIRE-FIGHTING SIGNS

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 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 23 of 24
Rev 0 1999

MEANING DESCRIPTION ILLUSTRATION

START BOTH ARMS ARE EXTENDED

ATTENTION HORIZONTALLY WITH THE PALMS
START OF FACING FORWARDS.
COMMAND

STOP THE RIGHT ARM POINTS UPWARDS WITH

INTERRUPTION THE PALM FACING FORWARDS.
END OF
MOVEMENT

END BOTH HANDS ARE CLASPED AT CHEST

OF THE HEIGHT.
OPERATION

FIGURE 7.6 GENERAL HAND SIGNALS

S:\H-SERIES\H-02\H02FigR0.XLS
 GENERAL ENGINEERING SPECIFICATION GES H.02
SAFETY SIGNS AND THEIR APPLICATIONS Page 24 of 24
Rev 0 1999

MEANING DESCRIPTION ILLUSTRATION

DANGER BOTH ARMS POINT UPWARDS WITH THE

EMERGENCY PALMS FACING FORWARDS.
STOP

QUICK ALL MOVEMENTS FASTER.

SLOW ALL MOVEMENTS SLOWER.

MOVE BOTH ARMS ARE BENT WITH THE PALMS

FORWARDS FACING UPWARDS, AND THE FOREARMS MAKE
SLOW MOVEMENTS TOWARDS THE BODY

MOVE BOTH ARMS ARE BENT WITH THE PALMS

BACKWARDS FACING DOWNWARDS, AND THE FOREARMS
MAKE SLOW MOVEMENTS AWAY FROM THE
BODY

RIGHT THE RIGHT ARM IS EXTENDED MORE OR LESS

TO THE HORIZONTALLY WITH THE PALM FACING
SIGNALMAN'S DOWNWARDS AND SLOWLY MAKES SMALL
MOVEMENTS TO THE RIGHT.

LEFT THE LEFT ARM IS EXTENDED MORE OR LESS

TO THE HORIZONTALLY WITH THE PALM FACING
SIGNALMAN'S DOWNWARDS AND SLOWLY MAKES SMALL
MOVEMENTS TO THE LEFT.

HORIZONTAL THE HANDS INDICATE THE RELEVANT

DISTANCE DISTANCE.

RAISE THE RIGHT ARM POINTS UPWARDS WITH THE

PALM FACING FORWARD AND MAKES A CIRCLE.

LOWER THE RIGHT ARM POINTS DOWNWARDS WITH

THE PALM FACING INWARDS AND MAKES A
CIRCLE.

VERTICAL THE HANDS INDICATE THE RELEVANT

DISTANCE DISTANCE.

FIGURE 7.7 DANGER HAND SIGNALS

S:\H-SERIES\H-02\H02FigR0.XLS
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.06

FIXED WATER SPRAY SYSTEMS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 2 of 16
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Application of Water Sprays 6
3.3 Cooling 7
3.4 Intensity Reduction 8
3.5 Emulsification 8
3.6 Water Curtains 8
3.7 Pipework Design 9

4.0 MATERIALS 10

4.1 Pipework and Fittings (General) 10

4.2 Spray Nozzles 10

5.0 MANUFACTURE 10

6.0 CO-ORDINATION 10

7.0 INSPECTION 11

7.1 Procedures 11
7.2 Scope 11
7.3 Nameplates (or Tagging) 11

8.0 TESTING 11

8.1 Statutory Tests 11

8.2 Test Procedures 12
8.3 Site Acceptance Test Requirements 12
8.4 Test Certificates 12
8.5 Test Equipment 12
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 3 of 16
Rev 0 1999

SEC TITLE PAGE

9.0 DOCUMENTATION 13

9.1 Introduction 13
9.2 Schedules and Reports 13
9.3 Data and Calculations 14
9.4 Drawings 14
9.5 Final Records, Documents and Manuals 14

10.0 PRIOR TO SHIPMENT 15

10.1 Painting and Coatings 15

10.2 Spares 16
10.3 Packing and Storage 16
10.4 Shipping 16
10.5 Warranty 16
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 4 of 16
Rev 0 1999

1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 The specification covers the minimum requirements for design, fabrication, inspection and testing for fixed
water spray systems installed on selected equipment for cooling and to reduce the intensity of heat in case
of fire.

1.1.2 The complete system will consist of fire water storage, pumps, ring mains, deluge valves and
pipework/spray systems which distributes water to the target area. This specification covers that section of
the system, downstream of the deluge valve which will normally be dry.

1.1.3 This specification applies to fixed water spray systems for refineries, onshore oil and gas installations and
processing facilities including items purchased either directly or as a part of a package.

1.1.4 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.5 In the event of any conflict between this specification and the Data Sheets, or with any of the applicable
codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification before proceeding with the work.

1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract together with any
Data Sheets, drawings or other attachments.

Exclusions

This specification does not cover the provision of sprinkler systems for the protection of buildings.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES H.01 - Fire Alarm Systems

GES H.04 - Fire Water Systems

GES H.07 - Fire-fighting Facilities For Storage Tanks

GES J.24 - Fire and Gas Instrumentation

GES N.04 - Fireproofing

GES P.01 - Piping Material Specification

GES P.02 - Plant Piping Systems

GES P.09 - Steel Piping Fabrication (Shop or Field)

GES P.10 - Erection and Testing of Steel Piping

GES X.01 - Surface Preparation and Painting Application

 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 5 of 16
Rev 0 1999

GES X.02 - Colour Coding of Equipment and Piping

GES X.03 - External Protective Coatings

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Water Spray System

A predetermined pattern of water spray based on droplet size distribution, spray density distribution and
coverage area produced by especially designed fixed nozzles arranged in a geometric configuration around
the equipment.

Passive Fire Protection (Fire Proofing)

Fire Protection of Plant equipment and supports by placing intermediate barriers. It may take the form of
inert material (e.g. concrete, vermiculite cement), intumescent or ablative coatings, or of a manufactured
heat resistant enclosures.

Active Fire Protection

It is the application of extinguishants or cooling mediums to control and/or extinguish a fire and/or to
protect adjacent equipment from damage. The mediums can be liquid (e.g. water, foam), gaseous (e.g.
carbon dioxide, steam, Halon) or solid (e.g. dry powder).

Critical Equipment

Critical equipment is equipment which, if it failed in a fire, would release material which in turn would:

(a) add significantly to the intensity of the fire;

(b) would increase the problem of fire-fighting;

(c) would make the consequences of the incident significantly worse.

NFPA

National Fire Protection Association

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 6 of 16
Rev 0 1999

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The design shall comply with this specification and the following Codes and Standards:

API 2021 - Guide for Fighting Fires in and around Flammable and Combustible
Liquid Atmospheric Storage Tanks

ASQ Q9000 - Quality Management and Quality Assurance

NFPA 15 - Water Spray Fixed Systems for Fire Protection

NFPA 25 - Inspection, Testing and Maintenance of Water Based

Fire Protection System

3.1.1 Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and Standards
at the time of the order should be used.

3.2 Application of Water Sprays

3.2.1 Water sprays can be applied in the following circumstances:

(a) to cool critical equipment;

For the most part such protection will be provided by Passive Fire Protection measures as per GES
N.04 but where for any reason such protection is lacking, active fire protection will be provided.
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 7 of 16
Rev 0 1999

(b) to reduce the heat intensity of a fire and control burning;

(c) in special cases, by directing water sprays at the surface of a burning pool of oil, to emulsify the
oil and thus extinguish the fire;

(d) to dilute the gas produced;

(e) to provide water curtains.

3.2.2 The key features of a well-designed spray system are:

- it delivers the required amount of water to the target area;

- it does not become blocked with rust or similar debris;

- the pipework itself is not destroyed by fire before it can come into service;

- the system can be tested and maintained regularly.

3.3 Cooling

Equipment to be cooled can be considered in the following categories:

3.3.1 Vessels in Process Areas

The amount and type of fixed spray protection which is justified will depend on plant layout, manning
levels, degree of regular operating inspection, availability of fire-fighting personnel (both full-time and
auxiliary) etc.

In general, a plant manned 24 hours per day will have a good level of surveillance and response, and it will
be necessary only to provide mobile and portable fire-fighting equipment (other than a fire main and
monitors). Where fixed spray protection is required it shall be provided at a rate of 0.25 US gal/min/ft² (10
litres/min/m²).

3.3.2 Structural Supports for Equipment, Pipelines, etc.

Typically, protection will be provided by passive fire protection (fire-proofing) with back-up from manual
intervention (monitors, hoses, as required).

3.3.3 Oil Storage Tank Protection

Tank cooling will normally be provided by means of mobile equipment or monitors. However, if the
tankage layout is congested, or if there is inadequate manpower available, then a fixed water spray system
should be provided.

Water shall be applied at the design rate of 0.25 US gal/min/ft² (10 litres/min/m²) to the tank roof (cone
roof tanks only) and walls.

To limit the consumption of water during tank fires, protecting adjacent is usually needless unless there is
direct flame contact or sufficient radiant heat to scorch the point. If there is a question about the
temperature and heat absorbtion of tank shells not directly exposed to flame, check frequently with water
spray from long-range water streams and see of steam is produced. If the metal steams, cooling water
should be applied until steaming stops (API 2021).
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 8 of 16
Rev 0 1999

3.3.4 LPG Storage

The particular danger to be protected against with LPG spheres is a BLEVE (Boiling Liquid Expanding
Vapour Explosion) in which a pressurised LPG vessel is engulfed in flames. Although the pressure relief
system should prevent the pressure from increasing greatly, the danger is that the metal of the sphere or
bullet above the liquid level will become overheated and will eventually fail, releasing large amounts of
liquid which immediately vaporises, usually with catastrophic results.

In order to guard against this contingency, fixed water spray systems shall be provided on all LPG storage
both pressurised and refrigerated, designed to deliver at a rate of 0.25 US gal/min/ft² (10 litres/min/m2).

For spheres, water delivery shall be either by horizontal rings of spray nozzles or by an open pipe deluge
into a `crown' weir on the top of the sphere. In the latter case, however, no credit can be taken for coverage
below the equator, and horizontal ring(s) of nozzles will have to be provided to give protection in this area.

For bullets, the spray nozzle array will be such as to ensure that the entire surface area is covered, including
the vessel ends and the shell below the mid-line.

3.4 Intensity Reduction

Fixed sprays shall be employed on all equipment which, statistically, are more likely to be involved in a
fire. Typically, pumps which are on hot oil duty (i.e. oil at above its auto-ignition temperature (AIT) or
410°F (210°C) (where AIT is not known) are vulnerable to fire arising from, for example, seal failure or
other leakage, and shall be provided with spray protection.

The water spray will be designed to deliver 0.25 US gal/min/ft² (10 litres/min/m2) over a plan area
extending 2 ft (0.6 m) in every direction from the pump body outline. At least one nozzle will direct water
onto the pump seal.

Facilities may be installed for the induction of foam concentrate to attempt to extinguish the fire, but
complete extinguishment will only occur when the flow of oil is cut off.

If steam is available at site, protection can also be provided by snuffing steam round the pump seals.

3.5 Emulsification

This technique should only be used on oil fires where the oil is of high flash point greater than 150°F
(> 66°C) and where it can be guaranteed that the oil will be physically restricted to the area under the water
spray.

Typically this technique is used only for the protection of oil filled electrical transformers and lubricating
oil systems.

Application rate shall be 0.25 US gal/min/m² (10 litres/min/m2) over the projected plan area.

3.6 Water Curtains

Water curtains can be set up either using a row of nozzles directed downwards or by nozzles at ground
level directed upwards, or a combination of the two.
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 9 of 16
Rev 0 1999

Water curtains can be used for three purposes:

(a) to present a barrier to heat radiated from a fire;

(b) to inhibit the flow of flammable or toxic gases;
(c) to protect evacuating personnel.

In the fire situation, large water droplets are more effective at absorbing heat as compared to a fine spray
which is more likely to be blown away by the wind or by the draughts caused by the fire itself.

Water curtains are, therefore, not reliable and should not be used as a heat barrier.

Water curtains can sometimes be effective in inhibiting the flow of vapours, but their performance can not
be reliably calculated and their use is not recommended.

3.7 Pipework Design

3.7.1 Pipework

The pipework system shall be designed such that after use, or testing, it will be possible to flush the system
with fresh water, and drain it down. (Purging and drying by air where possible).

Note:

Drain down is only necessary where:

(a) saline water is used;

(b) freezing conditions are expected.

Apart from these conditions, the system can remain full of water suitably dosed with corrosion inhibitor.

The designer will be required to demonstrate that surge pressures generated in the dry pipe system, when
the deluge valve is actuated, are within the design capacity of the system. Surge is reduced in piping which
is full of water.

Branches from the dry main to nozzles shall not be taken from the bottom of the pipe.

3.7.2 Spray Heads

Spray heads will be ½" (12.5 mm) minimum bore - threaded ½" (12.5 mm) N.P.T.

Where a significant `throw' is required or where the water spray is designed to emulsify high flash point
oils, the nozzles shall be of the `high velocity' design.

In other applications medium velocity or high velocity nozzles may be used.

- The detailed design of the nozzle locations and the resulting spray distribution pattern shall
indicate the overlapping coverage and ensure no dry areas.

- The spray head pressures range for which the distribution pattern is valid shall be stated and
hydraulic analysis of the system shall be carried out to demonstrate that the flow/pressure
characteristics are in compliance with the spray head requirements.

- The designer shall state the required amount of water which will take into account overlapping
coverage.
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 10 of 16
Rev 0 1999

4.0 MATERIALS

4.1 Pipework and Fittings (General)

Materials for piping/fittings specified in this section should be in compliance with the materials specified in
GES P.01.

Where long lengths of dry pipe could make the pipe vulnerable to overheating in a fire situation, because of
the time lag in filling the pipe, the dry pipe itself shall be protected by a linear heat detection system which
will initiate opening of the deluge valve.

- Cupro/Nickel (90/10) and duplex stainless steel are also technically acceptable.

4.2 Spray Nozzles

The following materials are acceptable for spray nozzles:

- brass or similar copper alloys;

- stainless steel.

Note:

Installations where sour gases may be present brass or other copper alloys are not acceptable.

5.0 MANUFACTURE

The manufacturer shall demonstrate that he has an adequate system of quality control, covering the
materials of manufacture, the manufacturing process and the testing of finished product (using sampling
procedures, where appropriate).

Preference shall be given to manufacturers (or their products) which have been approved by recognised
inspection authorities, or which have valid certification to the ASQ Q9000 series of specifications or
national equivalents.

6.0 CO-ORDINATION

6.1 The water spray is part of the overall fire protection system, and will only deliver the required protection if
other elements of the system are adequately designed.

The Owner will therefore ensure that in specifying the firewater system, the following have been taken into
account:

- a number of realistic fire scenarios have been considered in order to arrive at a rational
comprehensive basis for design;

- the availability of operations and maintenance personnel has been considered when plant and
equipment have been specified;

- an assessment has been carried out on the reliability of the electric power (and if appropriate, the
steam) supply;
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 11 of 16
Rev 0 1999

- an assessment of active versus passive fire protection has been carried out for the principal items
of equipment to be protected;

- the flow of large quantities of firewater containing oil can cause a fire to spread. It should,
therefore, be considered part of the design of the firewater system to ensure that the disposal of
water in the fire situation is properly allowed for;

- the firewater supply and pressure are adequate to meet the requirements of the water spray and all
fire fighting equipment which will be used simultaneously;

- the fire detection systems which will actuate the water spray are properly specified.

7.0 INSPECTION

7.1 Procedures

The inspection requirements are covered by the document "General Conditions of Purchase" which forms
part of the Purchase Order/Contract. Additional requirements are given below.

The Vendor/Contractor shall allow the Inspector free access of all areas of manufacture, fabrication,
assembly and testing.

The Vendor/Contractor always has the responsibility to provide adequate quality control and inspection of
equipment and materials. Any inspection by the Owner or his Inspector shall not relieve the
Vendor/Contractor of these responsibilities or those under his guarantees.

7.2. Scope

Refer to the specific inspection requirements for the main equipment.

7.3 Nameplates (or Tagging)

Where possible the equipment shall have a nameplate showing the following minimum information:

(a) the equipment vendors details;

(b) equipment plant item number;
(c) flow rate;
(d) pressure rating.

Inspector shall ensure that any shortcomings in the Vendor/Contractor's documentation or data are rectified
before any equipment or material is accepted for shipment.

8.0 TESTING

8.1 Statutory Tests

For pressure containing equipment:

The pressure tests shall be carried out in the presence of Owner's Inspector.
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 12 of 16
Rev 0 1999

8.2 Test Procedures

8.2.1 The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval prior to the
start of the testing programme.

8.2.2 All factory produced items and components shall be tested prior to leaving the factory.

8.2.3 The Owner shall have the right to witness all scheduled tests, and the supplier shall give 10 days notice of
all such tests.

8.2.4 Following the failure of any material or equipment to meet the test requirements, the Vendor/Contractor
shall submit in writing, without delay, his proposal (including a time table) for rectifying the situation.

8.3 Site Acceptance Test Requirements

8.3.1 Test Schedules

The Vendor/Contractor shall submit a schedule of Site Acceptance Tests that are to be undertaken to ensure
that the equipment is satisfactory.

The test schedules shall be approved by the Owner. There shall be a separate set of acceptance tests for
each unit supplied.

8.3.2 Initial Acceptance Tests

The initial acceptance tests shall be performed by the Vendor/Contractor when all relevant equipment has
been installed.

8.3.3 Final Acceptance Tests

Fourteen days after the system have been put into service, or fourteen days after the initial acceptance tests,
whichever is the earliest, the Final Acceptance Tests shall be effected by the Vendor/Contractor, and be
witnessed by the Inspector.

8.4 Test Certificates

8.4.1 Test Certificates

Final acceptance of the system will be given following satisfactory Final Acceptance Tests.

All copies of test certificates shall be furnished with final drawings as called for in the documentation
section. The Final Acceptance Tests shall be witnessed by the Inspector who shall retain one copy of the
certified tests.

8.5 Test Equipment

8.5.1 Supply

The Vendor/Contractor shall supply a set of test equipment if it is required.

 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 13 of 16
Rev 0 1999

8.5.2 Test Accessories

All necessary test accessories shall be provided.

Note:

All instrument and apparatus used in the performance of the tests shall have been calibrated to an agreed
standard at a laboratory of National standing within the period of 15 months of the test date. The cost of
carrying out such calibrations shall be borne by the Vendor/Contractor in all cases.

9.0 DOCUMENTATION

9.1 Introduction

9.1.1 This section covers the documentation required for the design, fabrication, inspection and testing for the
equipment.

9.1.2 The detailed list of documents that will be required will be attached to the Purchase Order/Contract.

9.2 Schedules and Reports

9.2.1 The Vendor/Contractor shall supply a schedule showing the documents for review and approval, proposed
Sub-Vendors/Sub-Contractors and material procurement and a production/fabrication programme.

9.2.2 The Vendor/Contractor shall submit his Quality Control Plan at the start of the contract.

9.2.3 Full documentation of all activities shall be made and it is the Vendor/Contractor's responsibility to collate
all documentation and certification and to generate and issue data books in accordance with the Purchase
Order/Contract requirements.

9.2.4 As a minimum the data books shall include the following as applicable:

(a) drawings showing:

- the pipework layout, location of nozzles and materials of construction;
- the method of supporting and anchoring pipework.

(b) Data Sheets for all items of equipment;

(c) Data Sheets for all chemicals and materials;

(d) a process flow diagram showing flow data and properties of fluids;

(e) a piping and instrumentation diagram;

(f) list of parts;

(g) static and dynamic loadings on support structures;

(h) maintenance and inspection schedules;

(i) list of spares required for start-up;

 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 14 of 16
Rev 0 1999

(j) details of any special equipment or tools required for the operation or maintenance of the system;

(k) operating schedules;

(l) drawings and schedules showing how heavy items of equipment can be removed and replaced.

9.3 Data and Calculations

9.3.1 The Vendor/Contractor shall provide a clear description of how he intends to ensure that water pressures
are controlled to safe but adequate levels.

9.3.2 The Vendor/Contractor shall supply with his tender completed Data Sheets containing all the relevant
information necessary for appraisal of the design by the Owner.

9.3.3 Project specific instructions will be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted, and the methods of submission.

9.3.4 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.

9.3.5 All calculations shall be carried out in clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be
clearly referenced.

9.3.6 Computer calculations will only be acceptable if all input is shown, together with calculated values of
intermediate terms and factors and options chosen, as well as final calculated dimensions, stresses or other
values and the computer program has been validated to the satisfaction of the Owner.

9.3.7 Calculations and drawings that are interdependent, i.e. foundation loading and equipment footprint, shall be
presented for appraisal together.

9.4 Drawings

9.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
and/or the Inspection Authority for review and approval.

9.4.2 The components and process to produce the ordered equipment shall be shown in sufficient detail to be
fully appraised e.g. outline drawings, components list and schematic.

9.4.3 General arrangement drawings shall be to scale and show the relative location and main dimensions of all
components including elevations.

9.4.4 Detail drawings which may be included on the general arrangement shall include thickness and dimensions
of all components.

9.4.5 As-built drawings may be the general arrangement drawings marked-up with the actual as-built dimensions.

9.5 Final Records, Documents and Manuals

9.5.1 Two copies of the Data Dossier shall be supplied, and shall be a record of the manufacturing process.
Where stated in the Purchase Order/Contract, besides the documents itemised in Section 9.2.4, it shall
contain the following:
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 15 of 16
Rev 0 1999

- general arrangement drawings and bill of material;

- the quality control plan;
- material certificates;
- positive material identification certificates;
- NDT procedures and records;
- hazardous areas certificates;
- performance test procedures and test certificate;
- non-conformity records;
- approvals by the Independent Inspection Authority;
- certificate of conformity;
- Owner's release certificate.

9.5.2 Six sets of the Installation, Operations and Maintenance Manual (IOM) shall be specifically compiled for
the equipment supplied. A compendium of manufacturer's data for a range of like products is not
acceptable. The IOM shall contain the following:

- a description of the equipment;

- the master document list and certified copies of key drawings;
- packing, shipping and site preservation instructions;
- step by step installation instructions;
- step by step pre-commissioning procedures;
- step by step commissioning procedures;
- step by step procedures for dismantling and re-assembly;
- routine preventive maintenance schedule and major repair procedures;
- list of special tools;
- spare parts ordering information.

The IOMs shall be presented in A4 format, and be securely bound in heavy duty 4-ring binders.

9.5.3 The Vendor/Contractor shall produce as-built documents revised to indicate field changes.

9.5.4 The Vendor/Contractor shall supply one set of mylar original drawings.

9.5.5 Electronic Data Format (EDF)

All documentation (drawings, calculations and Data Sheets etc) shall be produced by the
Vendor/Contractor in electronic format.

The format shall be compatible with that used by the Owner and shall be agreed at the commencement of
the contract.

In addition to the 'hard copies' required under the contract, copies of the electronic records shall be issued to
the Owner for all approved documentation, this forming part of the Vendor/Contractor's contractual
obligations.

10.0 PRIOR TO SHIPMENT

10.1 Painting and Coatings

Surface preparation, painting and painting materials shall be in accordance with GES X.01, GES X.02 and
GES X.03.
 GENERAL ENGINEERING SPECIFICATION GES H.06
FIXED WATER SPRAY SYSTEMS Page 16 of 16
Rev 0 1999

10.2 Spares

The Vendor/Contractor shall submit with his proposal a priced list of recommended spares for start-up and
two years operation for review by Owner.

10.3 Packing and Storage

This section describes the minimum requirement for the preservation and protection of the equipment
during sea and land transportation and storage, prior to installation.

The probable storage period will be specified in the order/enquiry and will extend from the time of despatch
to the time of unpacking at site. If the storage period is not stated, a minimum period of 24 months shall be
assumed. Packing to be suitable for sea freight.

The Vendor/Contractor shall submit his procedures for packing and preservation for review by the Owner.
The following preparation for shipment shall be a minimum requirement:

(a) after mechanical completion at the works, the equipment shall be left in a clean dry condition;

(b) the Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent
damage during shipment;

(c) machined or threaded exterior surfaces shall be protected during shipment and subsequent storage
with a rust preventer which is easily removed with a petroleum solvent;

(d) threaded end or socket welding end connections shall be fitted with metal, wood or plastic plugs or
caps;

(e) flanges shall be protected over the entire flange surface by protectors which are securely attached
to the flange.

The Vendor/Contractor shall submit his procedures for packing and preservation for review by the Owner.

10.4 Shipping

Detailed shipping arrangements are covered by the Purchase Order/Contract.

The equipment shall not leave the Vendor/Contractor's works for shipment until the release has been
approved by the Owner's Inspector.

10.5 Warranty

The Vendor/Contractor shall warrant all materials and services supplied against any defect for a minimum
of twelve (12) months after commissioning or twenty-four (24) months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated with
restoring the equipment to the standard specified by the Purchase Order/Contract.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.07

FIRE-FIGHTING FACILITIES FOR STORAGE TANKS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 2 of 26
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4
1.3 Data Sheets 4
1.4 Facilities Excluded 5
1.5 Economic Assessment 5

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 6

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Floating Roof Tanks 7
3.3 Cone Roof Tanks 9
3.4 Other Tank Safety Considerations 12

4.0 MATERIALS 12

4.1 Pipework and Fittings (General) 12

4.2 Dry Pipe (Foam to Storage Tank) 12
4.3 Dry Risers (Foam to Storage Tank Nozzle) 12
4.4 Foam Equipment 12

5.0 FABRICATION AND ASSEMBLY 13

5.1 Manufacturing Process 13

5.2 Certification 13

6.0 CO-ORDINATION 13

6.1 Fire Fighting Facilities 13

7.0 INSPECTION 13

7.1 Procedures 13
7.2 Scope 14
7.3 Nameplates (or Tagging) 14

8.0 TESTING 14

8.1 Statutory Tests 14

8.2 Test Procedures 14
8.3 Site Acceptance Test Requirements 14
8.4 Test Certificates 15
8.5 Test Equipment 15
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 3 of 26
Rev 0 1999

SEC TITLE PAGE

9.0 DOCUMENTATION 16

9.1 Introduction 16
9.2 Schedules and Reports 16
9.3 Data and Calculations 17
9.4 Drawings 17
9.5 FInal Records, Documents and Manuals 17

10.0 PRIOR TO SHIPMENT 18

10.1 Painting and Coatings 18

10.2 Spares 18
10.3 Packing and Storage 18
10.4 Shipping 19
10.5 Warranty 19

11.0 FIGURES SUB-INDEX 19

Figures 21
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 4 of 26
Rev 0 1999

1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for design, fabrication, inspection and testing for the
fixed fire-fighting facilities installed on crude and other hydrocarbon storage tanks.

1.1.2 This specification applies to Fire-fighting Facilities for Storage Tanks for refineries, onshore oil & gas
installations and processing facilities including items purchased either directly or as part of a package.

1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.4 In the event of any conflict between this specification and the data sheets, or with any of the applicable
codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification before proceeding with the work.

1.1.5 This General Engineering Specification will form part of the Purchase Order/Contract together with any
Data Sheets, diagrams or other attachments.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES A.01 - Plant Layout and Spacing

GES H.01 - Fire and Gas Alarm Systems

GES H.04 - Fire Water Systems

GES H.06 - Fixed Water Spray Systems

GES J.24 - Fire and Gas Detection Instrumentation

GES P.01 - Piping Material Specifications

GES P.02 - Plant Piping Systems

GES P.09 - Steel Piping Fabrication (Shop or Field)

GES P.10 - Erection and Testing of Steel Piping

GES X.01 - Surface Preparation and Painting

GES X.02 - Colour Coding of Equipment and Piping Systems

GES X.03 - External Protective Coatings

1.3 Data Sheets

The technical data supplied by the Owner with the NOC Specifications for the associated equipment is
given on the Data Sheets which are included at the end of these specifications. Where relevant, the
Vendor/Contractor shall complete the Data Sheets with the remaining information.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 5 of 26
Rev 0 1999

1.4 Facilities Excluded

This specification does not cover the provision of fire pumps, fire main etc. which are covered in GES H.04
and it is assumed that an adequate and reliable water supply is available.

1.5 Economic Assessment

The level of protection specified in this specification does not imply that all crude and hydrocarbon storage
tanks need to be protected to the same degree. For individual installations, the level of protection will
generally depend on an "Economic Assessment" based on the value of the tank content, the installation cost
of the tank, the operational value of the tank, the available fire fighting facilities at site and the cost of tank
protection.

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Floating Roof Tank

An open-top cylindrical storage tank where the roof is either of the double-deck or pontoon design, floating
on the surface of the tank contents. A seal will be fitted between the edge of the roof and the tank shell to
reduce loss of product vapour to the atmosphere and to restrict the formation of flammable mixtures above
the liquid surface.

Cone Roof (Fixed Roof) Tank

A cylindrical storage tank where a coned roof is welded to the top of the shell.

Foam Eductor

A device for drawing foam concentrate into the fire water stream at a controlled rate to produce an
unaspirated foam mix.

Foam Generator

A device for drawing air into unaspirated foam at a controlled rate to produce aspirated (`finished') foam.

High Back Pressure Foam Generator

A device capable of inducing air into a liquid stream which is discharging against a head of liquid in the
tank.

Central Fire and Gas Monitoring System

An electronic processing unit which on receipt of signals from fire, flammable gas or other alarm signals,
transmits Signals to a predetermined programme to indicate the status of plant areas, and to initiate action
(emergency actions e.g. start fire pump on confirmed receipt of fire alarm) as required.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 6 of 26
Rev 0 1999

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

3.1.1 American Codes and Standards

The design shall comply with this specification and the following Codes and Standards:

NFPA 11 - National Fire Code, Low Expansion Foam

NFPA 15 - National Fire Code, Water Spray Fixed Systems

NFPA 25 - Standard for the Inspection, Testing and Maintenance of Water-Based Fire
Protection Systems

NFPA 30 - Flammable and Combustible Liquid Code

API 521 - American Petroleum Institute, Guide for Pressure Relieving and Depressuring
Systems
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 7 of 26
Rev 0 1999

API 2021 - Guide for Fighting Fires in and around Flammable or Combustible Liquid
Atmospheric Storage Tanks

ASQ Q9000 - Quality Management and Quality Assurance

3.1.2 Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and Standards
at the time of the order shall be used.

3.2 Floating Roof Tanks

3.2.1 Introduction

Well-maintained floating roof tanks are generally low-risk items. The weak point in the design however, is
the gap between the edge of the roof and the tank shell where the rim-seal is fitted and where potentially
the flammable vapours from the tank contents come into contact with air.

The vast majority of fires on floating roof tanks emanate from this rim-seal area and in almost all cases
properly designed equipment and procedures will allow a fire in this area to be controlled and extinguished
before it can spread to the main roof area.

In the absence of fixed fire fighting equipment, the rim-seal fires are fought manually (particularly on
smaller tanks) by properly equipped and well-trained personnel from the roof girder, or by projecting foam
solution on to the roof from a monitor.

This specification, however, assumes that the intention is to install fixed equipment to control the fire while
the personnel involved can remain outside the bund area.

All facilities will be designed on the basis of using 3% foam concentrate.

3.2.2 Where Manual Intervention is Available

The system shall consist of a dry pipe commencing from a pump-in point outside the tank bund. A foam
concentrate eductor shall be installed in the line, also outside the bund. (See Typical Flow Diagram for
manual, Top Foam Pouring System - Figure No 11.2).

The dry pipe shall run across the in-bund area to the shell of the tank, and then up the outside of the tank to
feed a ring main running round the tank at wind girder level.

Notes:

1. All foam lines in a bund area shall be fabricated from carbon steel minimum `Standard Weight'
pipe.

2. All foam lines to slope to a valved drain point.

A number of foam delivery systems, each consisting of a foam generator and a foam pourer, shall be
connected to the ring main to deliver aspirated foam down the inside of the tank wall onto the rim-seal area
of the roof. The foam will be retained against the tank shell by a circular foam dam welded to the roof of
the tank.

(a) Foam Concentrate Eductor

An in-line eductor, operating on the Venturi principle, shall be provided to draw the foam
concentrate into the water system.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 8 of 26
Rev 0 1999

The pipe work shall be arranged to allow straight lengths of water pipe before and after the
eductor equal to 5 pipe diameters. The eductor shall be fitted with a non-return valve in the
concentrate pick-up line.

A foam generator shall be provided to draw air into the foam concentrate solution, at the correct
ratio, to produce aspirated foam.

Foam pourers shall be designed to deliver the finished aspirated foam in a tight cohesive stream
which runs down the inside of the tank shell.

The mouths of the pourers shall be fitted with mesh to discourage birds from nesting and shall be
equipped with wind shields.

Pourers shall be located no more than 79 ft (24 m) apart, and shall be evenly spaced around the
circumference.

(b) Foam Dam

Foam dams shall be fitted to floating roofs and shall comply with NFPA 11, Section A-3-2.11.1
(c). They will be located 2 ft. (610 mm) from the edge of the roof. The height of the dam will be
2 ft. (610 mm), or 2" (50 mm) above the highest point of the rim-seal mechanism, whichever is the
greater. The height of the dam may be increased by up to 4" (100 mm) for a distance of 6 ft.
(1.8m) each side of each foam delivery point, to cope with impingement of the foam.

The dam shall be fitted with drainage slots as specified in NFPA 11.

(c) Equipment Sizing

The system shall be sized to deliver the non-aspirated foam to the annular area between the tank
shell and the foam dam at the rate of 0.30 US gal/min/ft2 (12 litres/min/m2) for a minimum period
of 20 mins.

(d) Foam Concentrate Storage

Unless adequate arrangements are made for the bulk storage and delivery of foam concentrate,
provision shall be made for the handling and locating of concentrate drums such that they can
readily be connected to the eductor pick-up pipe.

Facilities shall be provided for sufficient concentrate for 20 minutes application at design rates.

3.2.3 Where No Manual Intervention is Available

The basic equipment for delivering the foam to the rim-seal will be similar to that for fighting the fires with
manual intervention (Section 3.2.2) but with the following amendments and additions. (See Typical Flow
Diagram for Automatic Top Foam Pouring System - Figure No 11.1).

(a) A Balanced Pressure Foam Proportioner will be used to control the flow of foam concentrate into
the fire water stream.

(b) Where no manual interruption is available, a reliable fire detection system shall be provided in
accordance with GES H.01 and GES J.24.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 9 of 26
Rev 0 1999

(c) A pumped system comprising two pumps (one duty and one standby) shall be provided to inject
foam concentrate into the water stream. The pump shall be electrically driven and the motor shall
be on the emergency power supply.

The foam concentrate pump and pipework system will be designed to deliver the concentrate to the
foam proportioner at a pressure at least 15 psi (103 kPa) greater than the fire water supply pressure
in the ring main.

(d) The foam concentrate shall be stored in one or more bulk storage tanks, each connected to a pump
discharging to a distribution system serving one or more tanks, installation (Minimum 2 required;
1 duty and 1 standby).

(e) Concentrate storage shall be sized to hold at least a total storage of 40 minutes supply (comprising
20 minutes normal and 20 minutes standby supply) to the largest crude or hydrocarbon storage
tank protected.

(f) The foam system shall be fed from the fire main with a deluge valve installed in the water off-take
to each tank. Weep holes shall be provided downstream of the deluge valve to drain away any
leakage.

A control valve shall be fitted in the concentrate line to each tank system.

On receipt of a fire signal at the control unit (central fire panel), the firewater and foam
concentrate pumps shall be started automatically, and the relevant water deluge valve and
concentrate control valve opened.

The pumps and valves shall also be operable manually.

Notes:

1. All foam lines in a bund area shall be fabricated from carbon steel minimum 'Standard Weight'
pipe.

2. All foam lines to slope to a valved drain point.

3.3 Cone Roof Tanks

3.3.1 Introduction

Liquids such as Crude Oil and Fuel Oil shall not be stored in fixed roof tanks larger than 150 ft (45.7
metres) unless an inerting system is provided.

There are two standard systems for delivering foam to the surface of the oil in a cone roof tank in the event
of fire:

(a) by means of a top pouring system whereby foam solution is aerated in a foam generator and
poured by means of a pipe which penetrates the tank shell close to the roof, on to the surface of the
oil;

(b) a base (sub-surface) injection system in which aspirated foam is pumped into the base of the tank,
either through a dedicated line or an existing product line, and rises through the oil to form a
blanket on the surface of the liquid.

The top pouring equipment is vulnerable to damage from an explosion which may accompany or precede a
fire, and is therefore only recommended when base injection is not possible.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 10 of 26
Rev 0 1999

Base injection is therefore recommended, except where:

(a) the viscosity of the tank contents is too great to allow the passage of the foam through the oil
(generally taken to above 440 cS at the minimum anticipated operating temperature);

(b) the stored fuel is miscible with water, e.g. alcohols.

All facilities will be designed on the basis of using 3% foam concentrate.

3.3.2 Where Manual Intervention is Available (Base Foam Injection)

The system shall consist of a pump-in point for firewater, an induction system for drawing foam
concentrate into the water stream and a High Back Pressure Foam Generator for drawing air into the foam
solution. This equipment will be located outside the tank bund. (See typical flow diagram for manual Base
Foam Injection System - Figure No 3).

The expanded foam may be delivered to the tank by means of an existing product line, but if no line of
adequate size exists, then a dedicated foam line must be provided.

Any valves in the system must be either locked open or operable from outside the bund, and a bursting disc
shall be installed in the foam line to provide a positive seal against the tank content escaping into the foam
pipework.

A T-piece and valve shall be installed in the line before the disc to allow for testing the foam generation
system and sampling the foam.

(a) Equipment Sizing

The system shall be sized to deliver foam at a rate of 0.10 - 0.20 US gal/min/ft2 (4-8 litres/min/m2)
based on the surface area of the fluid stored.

(b) Foam Concentrate Eductor

An in-line eductor, operating on the Venturi principle, will be provided to draw the foam
concentrate into the water stream.

The pipework shall be arranged to allow straight lengths of water pipe before and after the eductor
equal to 5 pipe diameters. The eductor should be fitted with a non-return valve in the concentrate
pick-up line.

(c) High Back Pressure Foam Generator (HBPFG)

The HBPFG shall be located in a horizontal section of the pipework located such that the air
intake is on the top of the pipe.

There shall be five diameters length of straight pipe upstream and downstream of the generator.

A non-return valve shall be inserted in the air intake to prevent any leakage of fuel or foam.

(d) Pipework

A non-return valve shall be fitted in the foam solution pipework between the HBPFG and the
storage tank to prevent back-flow of product.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 11 of 26
Rev 0 1999

The delivery pipework shall be sized such that the velocity of the aspirated foam, assuming an
expansion ratio of 4:1, does not exceed 19.7 ft/sec (6 m/sec).

If the tank diameter is greater than 76 ft. (24 m), then more than one foam discharge outlet is
required, as given in Section 3.2.6.3 of NFPA 11. The foam shall be released into the fluid
sufficiently above the tank floor to ensure that it does not come into contact with any water at the
bottom. The foam should be directed either horizontally or vertically up.If more than one foam
discharge point is required they should be evenly distributed round the circumference of the tank.
This shall be achieved by having an internal distribution ring in the tank directing the foam
upwards towards the tank shell.

(e) Foam Concentrate Storage

Unless adequate arrangements are made for the bulk storage and delivery to the eductor of the
concentrate, provision shall be made for the handling and locating of concentrate drums such that
they can readily be connected to the eductor pick-up pipe.

Facilities shall be provided for sufficient concentrate for 55 minutes application at design rates,
except that, if the Flash Point of the oil is greater than 100°F (38°C), only 30 minutes supply of
concentrate need be held.

3.3.3 Where No Manual Intervention is Available (Base Foam Injection)

The basic equipment for delivering the foam to the tank base will be similar to that for fighting the fires
with manual intervention (Section 3.2.2 above), but with the following amendments and additions (See
typical flow diagram for automatic Base Foam Injection System - Figure No 4):

(a) Where no manned intervention is available, a reliable fire detection system shall be provided in
accordance with GES H.01 and GES J.24.

(b) The foam system shall be fed from the fire main with a deluge valve installed in the water off-take.
Weep holes shall be provided downstream of the deluge valve to drain away any leakage.

(c) A pumped system will be provided to inject foam concentrate into the water stream. The pump
shall be electrically driven and the motor shall be on the emergency power system.

The foam concentrate pump and pipework system will be designed to deliver the concentrate to the
foam proportioner at a pressure at least 15psi (103 kPa) greater than the supply fire water pressure.

A control valve, normally closed, shall be installed in the concentrate line to the foam eductor.

The foam concentrate will be stored in one or more bulk storage tanks, each connected to a pump
discharging to a distribution system.

Concentrate storage will be sized to hold at least 55 minutes supply to the largest tank in the
protective system, except that if the Flash Point of the oil is greater than 100°F (38°C) only 30
minutes supply of concentrate need be held.

(d) The control unit will be programmed such that on receipt of a fire signal, it will initiate start-up of
the fire water and foam concentrate pumps, and opening of the water deluge valve and concentrate
control valve.

(e) A proprietary Balanced Pressure Foam Proportioner will be used to control the flow of concentrate
into the fire water stream.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 12 of 26
Rev 0 1999

(f) The firewater pump and foam concentrate pump, and the firewater deluge valves and foam
concentrate control valves shall be able to be operated manually.

3.3.4 Top Pouring of Foam in Cone Roof Tanks

When the oil contents are miscible with water, or when the viscosity of the oil is greater than 440 cS, then
foam application shall be by top pourer.

The equipment shall be designed in accordance with NFPA 11.

3.4 Other Tank Safety Considerations

3.4.1 Fire Spread

Historically, in almost half the tank fires which occur, the fire spreads to one or more adjacent tanks,
thereby increasing the difficulty of achieving extinction, and also increasing the cost of the damage and
disruption arising from the incident.

3.4.2 Tank Spacing

Protection against fire spread can be achieved by having adequate spacing between tanks. See GES A.01.

3.4.3 Water Spray Application

For storage tank cooling details see GES H.06.

4.0 MATERIALS

4.1 Pipework and Fittings (General)

Materials for piping/fittings specified in this section should be in compliance with the materials specified in
GES P.01.

Note: Where long lengths of dry pipe could make the pipe vulnerable to overheating in a fire situation,
because of the time lag in filling the pipe, the dry pipe itself shall be protected by a linear heat
detection system which will initiate opening of the deluge valve.

4.2 Dry Pipe (Foam to Storage Tank)

Any buried section of dry pipe shall be of the same material as the buried fire main, with similar external
corrosion protection (e.g. coated, wrapped and cathodically protected).

4.3 Dry Risers (Foam to Storage Tank Nozzle)

The risers shall be of galvanised steel (providing the diameter is not less than NPS 2" (50mm)) and
facilities exist to flush the system with fresh water, if saline water is used in the fire water system or if
freezing temperatures are expected. Otherwise, risers can remain filled with inhibited fresh water.

4.4 Foam Equipment

The foam generator and top foam pourer shall be of cast iron or steel. The generator internals and pourers
protective mesh shall be of stainless steel.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 13 of 26
Rev 0 1999

5.0 FABRICATION AND ASSEMBLY

5.1 Manufacturing Process

The manufacturer shall demonstrate that he has an adequate system of quality control, covering the
materials of manufacture, the manufacturing process and the testing of finished product (using sampling
procedures, where appropriate).

5.2 Certification

Preference shall be given to manufacturers (or their products) which have been approved by recognised
inspection authorities, or which have valid certification to ASQ Q9000 or national equivalents.

6.0 CO-ORDINATION

6.1 Fire Fighting Facilities

Fire fighting facilities for storage tanks is only a part of the overall fire protection measures, and will only
deliver the required protection if the other elements of the system are in place.

The Owner will therefore ensure that in specifying the firewater system, the following have been taken into
account.

6.1.1 A number of realistic fire scenarios have been considered in order to arrive at a rational comprehensive
basis for design.

6.1.2 The availability of operations and maintenance personnel has been considered when plant and equipment
have been specified.

6.1.3 An assessment has been carried out on the reliability of the electric power (and if appropriate, the steam)
supply.

6.1.4 An assessment of active versus passive fire protection has been carried out for the principal items of
equipment to be protected.

6.1.5 The flow of large quantities of firewater containing oil can cause a fire to spread. It should, therefore, be
considered part of the design of the system that the drainage of water is properly allowed for.

6.1.6 The firewater supply and pressure is adequate to meet the requirements of all fire fighting equipment when
used simultaneously for the worst case.

7.0 INSPECTION

7.1 Procedures

The inspection requirements are covered by the document "General Conditions of Purchase" which forms
part of the Purchase Order/Contract. Additional requirements are given below.

The Vendor/Contractor shall allow the Inspector free access to all areas of manufacture, fabrication,
assembly and testing.
 GENERAL ENGINEERING SPECIFICATION GES H.07
FIRE-FIGHTING FACILITIES FOR STORAGE TANKS Page 14 of 26
Rev 0 1999

The Vendor/Contractor always has the responsibility to provide adequate quality control and inspection of
equipment and materials. Any inspection by the Owner or his Inspector shall not relieve the
Vendor/Contractor of these responsibilities or those under his guarantees.

7.2 Scope

Prior to testing, the following checks shall be carried out:

(a) all screwed and flanged joints shall be visually examined and checked for tightness;

(b) the assembly shall conform to the engineering flow diagrams;

(c) all pipe supports and guides have been correctly installed;

(d) the correct gaskets have been fitted in the flanged joints and all flange bolts have been installed
and tightened;

(e) all valves have been correctly installed.

7.3 Nameplates (or Tagging)

Where possible the equipment shall have a nameplate showing the following minimum information:

(a) the equipment vendors details;

(b) equipment plant item number;
(c) flow rate;
(d) pressure rating.

The Inspector shall ensure that any shortcomings in the Vendor/Contractor's documentation or data are
rectified before any equipment is accepted for shipment.

8.0 TESTING

8.1 Statutory Tests

For pressure containing equipment the pressure tests shall be carried out in the presence of Owner's
Inspector.

8.2 Test Procedures

8.2.1 The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval prior to the
start of the testing programme.

8.2.2. All factory produced items and components shall be tested prior to leaving the factory.

8.2.3 The Owner shall have the right to witness all scheduled tests, and the supplier shall give 10 days notice of
all such tests.

Any damage suffered by material or equipment (including test equipment) as a result of testing shall be for
the Vendor/Contractor's account.
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8.2.4 Following the failure of any material or equipment to meet the test requirements, the Vendor/Contractor
shall submit in writing, without delay, his proposal (including a time table) for rectifying the situation.

8.2.5 The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval prior to the
start of the testing programme.

8.3 Site Acceptance Test Requirements

8.3.1 Test Schedules

The Vendor/Contractor shall submit a schedule of Site Acceptance Tests that are to be undertaken to ensure
that the equipment is satisfactory.

The test schedules shall be approved by the Owner. There shall be a separate set of acceptance tests for
each unit supplied.

8.3.2 Initial Acceptance Tests

The initial acceptance tests shall be performed by the Vendor/Contractor when all relevant equipment has
been installed.

8.3.3 Final Acceptance Tests

Fourteen days after the system have been put into service, or fourteen days after the initial acceptance tests,
whichever is the earliest, the Final Acceptance Tests shall be effected by the Vendor/Contractor, and be
witnessed by the Inspector.

8.4 Test Certificates

8.4.1 Test Certificates

Final acceptance of the system will be given following satisfactory Final Acceptance Tests.

All copies of test certificates shall be furnished with final drawings as called for in the documentation
section. The Final Acceptance Tests shall be witnessed by the Inspector who shall retain one copy of the
certified tests.

8.5 Test Equipment

8.5.1 Supply

The Vendor/Contractor shall supply a set of test equipment if it is required.

8.5.2 Test Accessories

All necessary test accessories shall be provided.

Note:

All instrument and apparatus used in the performance of the tests shall have been calibrated to an agreed
standard at a laboratory of National standing within the period of 15 months of the test date. The cost of
carrying out such calibrations shall be borne by the Vendor/Contractor in all cases.
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9.0 DOCUMENTATION

9.1 Introduction

9.1.1 This section covers the documentation required for the design, fabrication, inspection and testing for the
equipment.

9.1.2 The detailed list of documents that are required will be attached to the Purchase Order/Contract.

9.2 Schedules and Reports

9.2.1 The Vendor/Contractor shall supply a schedule showing the documents for review and approval, proposed
Sub-Vendors/Sub-Contractors and material procurement and a production/fabrication programme.

9.2.2 The Vendor/Contractor shall submit his Quality Control Plan at the start of the contract.

9.2.3 Full documentation of all activities shall be made, and it is the Vendor/Contractor's responsibility to collate
all documentation and certification and to generate and issue data books in accordance with the Purchase
Order/Contract requirements.

9.2.4 As a minimum, these data books shall include the following where applicable:

- the pipework layout and materials of construction;

- the method of supporting and anchoring pipework;

- data sheets for all items of equipment;

- data sheets for all chemicals and materials;

- a process flow diagram showing flow data and properties of fluids;

- a piping and instrumentation diagram;

- list of parts;

- static and dynamic loadings on support structures;

- inspection and maintenance schedules;

- list of spares required for start-up;

- details of any special equipment or tools required for the operation or maintenance of the system;

- operating schedules;

- drawings and schedules showing how heavy items of equipment can be removed and replaced.

9.2.5 All appropriate documentation and certification necessary to complete the contract data shall be collated,
checked and authorised by the Inspector prior to despatch.
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9.3 Data and Calculations

9.3.1 The Vendor/Contractor shall provide a clear description of how he intends to ensure that water pressures
are controlled to safe but adequate levels.

9.3.2 The Vendor/Contractor shall supply with his tender completed Data Sheets containing all the relevant
information necessary for appraisal of the design by the Owner.

9.3.3 Project specific instructions will be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted, and the methods of submission.

9.3.4 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.

9.3.5 All calculations shall be carried out in clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be
clearly referenced.

9.3.6 Computer calculations will only be acceptable if all input is shown, together with calculated values of
intermediate terms and factors and options chosen, as well as final calculated dimensions, stresses or other
values and the computer program has been validated to the satisfaction of the Owner.

9.3.7 Calculations and drawings that are interdependent, i.e. foundation loading and equipment footprint, shall be
presented for appraisal together.

9.4 Drawings

9.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
and/or the Inspection Authority for review and approval.

9.4.2 The components and process to produce the ordered equipment shall be shown in sufficient detail to be
fully appraised e.g. outline drawings, components list and schematic.

9.4.3 General arrangement drawings shall be to scale and show the relative location and main dimensions of all
components including elevations.

9.4.4 Detail drawings which may be included on the general arrangement shall include thickness and dimensions
of all components.

9.4.5 As-built drawings may be the general arrangement drawings marked-up with the actual as-built dimensions.

9.5 Final Records, Documents and Manuals

9.5.1 Two copies of the Data Dossier shall be supplied, and shall be a record of the manufacturing process.
Where stated in the Purchase Order/Contract, besides the documents itemised in Section 9.2.4, it shall
contain the following:

- general arrangement drawings and bill of material;

- the quality control plan;
- material certificates;
- positive material identification certificates;
- NDT procedures and records;
- hazardous areas certificates;
- performance test procedures and test certificate;
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- non-conformity records;
- approvals by the Independent Inspection Authority;
- certificate of conformity;
- Owner's release certificate.

9.5.2 Six sets of the Installation, Operations and Maintenance Manual (IOM) shall be specifically compiled for
the equipment supplied. A compendium of manufacturer's data for a range of like products is not
acceptable. The IOM shall contain the following:

- a description of the equipment;

- the master document list and certified copies of key drawings;
- packing, shipping and site preservation instructions;
- step by step installation instructions;
- step by step pre-commissioning procedures;
- step by step commissioning procedures;
- step by step procedures for dismantling and re-assembly;
- routine preventive maintenance schedule and major repair procedures;
- list of special tools;
- spare parts ordering information.

The IOMs shall be presented in A4 format, and be securely bound in heavy duty 4-ring binders.

9.5.3 The Vendor/Contractor shall produce as-built documents revised to indicate field changes.

9.5.4 The Vendor/Contractor shall supply one set of mylar original drawings.

9.5.5 Electronic Data Format (EDF)

All documentation (drawings, calculations and Data Sheets etc) shall be produced by the
Vendor/Contractor in electronic format.

The format shall be compatible with that used by the Owner and shall be agreed at the commencement of
the contract.

In addition to the 'hard copies' required under the contract, copies of the electronic records shall be issued
to the Owner for all approved documentation, this forming part of the Vendor/Contractor's contractual
obligations.

10.0 PRIOR TO SHIPMENT

10.1 Painting and Coatings

Surface preparation, painting and painting materials shall be in accordance with NOC Specification GES
X.01, GES X.02 and GES X.03.

10.2 Spares

The Vendor/Contractor shall submit with his proposal a priced list of recommended spares for start-up and
two years operation for review by Owner.
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10.3 Packing and Storage

This section describes the minimum requirement for the preservation and protection of the equipment
during sea and land transportation and storage, prior to installation.

The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24 months
shall be assumed. Packing to be suitable for sea freight.

The following preparation for shipment shall be a minimum requirements.

(a) After mechanical completion at the works, the equipment shall be left in a clean dry condition.

(b) The Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent
damage during shipment.

(c) Machined or threaded exterior surfaces shall be protected during shipment and subsequent storage
with a rust preventer which is easily removed with a petroleum solvent.

(d) Threaded end or socket welding end connections shall be fitted with metal, wood or plastic plugs
or caps.

(e) Flanges shall be protected over the entire flange surface by protectors which are securely attached
to the flange.

10.4 Shipping

Detailed shipping arrangements are covered by the Purchase Order/Contract.

The equipment shall not leave the Vendor/Contractor's works for shipment until the release has been
approved by the Owner's Inspector.

10.5 Warranty

The Vendor/Contractor shall warrant all materials and services supplied against any defect for a minimum
of twelve (12) months after commissioning or twenty four (24) months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.

11.0 FIGURES SUB-INDEX

Figure No. 11.1 - Typical Flow Diagram For (Automatic) Top Foam Pouring System For Floating
Roof Storage Tanks

Figure No. 11.2 - Typical Flow Diagram For (Manual) Top Foam Pouring system For Floating
Roof Storage Tanks

Figure No. 11.3 - Typical Flow Diagram For (Manual) Base Foam Injection System For Cone
Roof Storage Tanks

Figure No. 11.4 - Typical Flow Diagram For (Automatic) Base Foam Injection System For
Cone Roof Storage Tanks
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Figure No. 11.5 - Typical Flow Diagram For (Automatic) Base Foam Injection System For
Cone Roof Storage Tanks

Figure No. 11.6 - Typical Flow Diagram For (Manual) Base Foam Injection System For Cone
Roof Storage Tanks
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 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.11

PROTECTIVE CLOTHING AND BA SETS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

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INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Other NOC Specifications 3

2.0 DEFINITIONS 4

2.1 Technical 4
2.2 Contractual 4

3.0 DESIGN 5

3.1 Codes and Standards 5

3.2 Assessing Requirements 5

4.0 GENERAL USE, CARE AND MAINTENANCE OF EQUIPMENT 6

4.1 General 6
4.2 Procedures 6
4.3 Personnel 7

5.0 SPECIFIC TYPES OF EQUIPMENT 8

5.1 Head Protection 8

5.2 Eye and Face Protection 9
5.3 Hearing Protection 10
5.4 Foot Protection 12
5.5 Hand and Arm Protection 14
5.6 Body Protection 14
5.7 Safety Belts, Harnesses and Lines 16
5.8 Life Jackets and Buoyancy Aids 17
5.9 Breathing Protection 18

6.0 EQUIPMENT PURCHASE 22

6.1 Design and Construction 22

6.2 Inspection and Testing 22
6.3 Documentation 22
6.4 Spares 23
6.5 Packing and Shipping 23
6.6 Warranty 23
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the general requirements for protective clothing and breathing apparatus (BA)
sets.

1.1.2 This specification applies to protective clothing and BA sets for Refineries, Onshore Oil and Gas
Installations, and Processing Facilities.

1.1.3 This specification does not cover :

- ordinary clothes and uniforms provided for the primary purpose of presenting a corporate image,
- portable devices for detecting and signalling risks (e.g., personal gas detectors or radiation
dosimeters), or
- protective equipment for protection for radio-active hazards, road travel, kitchen hygiene, or
sports.

1.1.4 The provision of protective clothing and BA sets shall be based upon the following:

a) Personal protection equipment shall be provided at all places of employment to ensure the
adequate and appropriate provision of personal protection where this cannot be achieved by better
means.

b) The provision of personal protection equipment shall be treated as the last resort to minimise risks
and shall not be considered as a substitute for:

- best possible engineering controls, and

- safe working procedures,
which shall always be developed first.

c) When comparing the protection provided by personal protection equipment with that provided by
good engineered controls and safe working procedures, full account shall be taken of the
following:

- personal protection equipment protects only the individual wearing it,

- its effectiveness is:
- difficult to assess, and
- dependant on it being used properly and consistently.

d) Throughout this specification, details of relevant British Standards have been included for entry
into Purchase Orders and operating procedures as appropriate. The inclusion of this information is
not intended to be restrictive.

1.2 Other NOC Specifications

The following NOC specifications are an integral part of this specification and any exceptions shall be
approved in advance by the Owner:

GES A.04 Noise Level Criteria and Noise Control

GES H.02 Safety Signs and their Applications

GES H.09 Emergency Shower and Eyewash Facilities

2.0 DEFINITIONS
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2.1 Technical

The technical terms used in this specification are defined as follows:

Protective clothing

The term protective clothing shall mean all clothing and personal equipment which is intended to be worn
or held by a person at work to protect him against risk from that work to his health or safety.

BA Set

A system which permits the wearer to carry a limited supply of breathable air with him into a hazardous or
potentially hazardous location.

Personal Protection Equipment

Within the context of this specification, personal protection equipment (PPE) shall mean all protective
clothing and BA sets which fall within its scope.

Hazard

The potential to cause harm.

Consequence

The likely severity of harm from a particular hazard.

Frequency

The likelihood that a particular hazard will occur.

Risk

A multiple of consequence and frequency, a high risk thus incorporating a high likely severity and a high
likelihood of occurrence.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

2.2.1 Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

2.2.2 Vendor

The company supplying the equipment and material.

2.2.3 Contractor

The main contractor for a defined piece of work

2.2.4 Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.
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2.2.5 Inspection Authority

The organisation representing the Owner or Contractor that verifies that the equipment and facilities have
been designed, constructed, inspected and tested in accordance with the requirements of this specification
and the Purchase Order/Contract.

2.2.6 Inspector

A qualified individual representing the Owner, Contractor or the assigned Inspection Authority, who
verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

In view of the large number of standards dealing with protective clothing and BA Sets, relevant British
Standards have been included in Section 5.0 under specific equipment headings.

3.2 Assessing Requirements

3.2.1 In assessing the required level of personal protection equipment to be provided at a given location as a
whole, the following shall be considered:

- the workplace hazards and risks, particularly those presented by:

- hazardous materials,
- new constructions,
- non-routine activities, and
- dangerous machinery,
- the numbers, types and geographical distribution of people usually present,
- the needs of travelling and remote workers and night shift workers,
- accident history at the location (number, type, frequency and severity), and
- the remoteness of the location from back-up support.

3.2.2 In assessing the personal protection equipment to be provided for a given task, the following shall be
considered:

- the nature of the task

- the physical effort required to do the task,
- the methods of work, and
- requirements for mobility, visibility and communication.

3.2.3 The personal protection equipment provided to an individual shall:

- be appropriate for the risks involved,

- take account of ergonomic requirements, and
- SHALL NOT increase the overall risk to him.

3.2.4 Dependant only on the risks associated with the work to be done, personal protection equipment shall be
equally available to all persons on the premises who may be exposed to a risk to their health or safety
whilst on the premises, regardless of whether they are employees, contractors, visitors or others, (which
shall not in any way indicate any legal liability).

3.2.5 Personal protection equipment shall be provided without charge to the worker required to use it.
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3.2.6 All persons required to use personal protection equipment shall be adequately instructed in its use and care,
with no charge for such instruction.

3.2.7 Where personal protection equipment is required, there shall be a reliable system in place for its training,
provision, storage, distribution, inspection, maintenance and replacement.

3.2.8 Personal protection equipment provided at each location shall be re-assessed at least every 3 years (or more
frequently if required by legislation), and before any significant change in the activities at the location.

4.0 GENERAL USE, CARE AND MAINTENANCE OF EQUIPMENT

4.1 General

4.1.1 All personal protection equipment shall be:

- designed, constructed, tested and approved to a recognised standard,

- suitably marked in Arabic and English.
- easily accessible,
- in good order at all times, and
- used only by those trained to do so.

4.1.2 The Company's Hazardous Materials Manual shall be used as the base document when assessing the
personal protection equipment required to work with a specific hazardous material.

4.2 Procedures

4.2.1 The use, care and maintenance of personal protection equipment shall be appropriately and adequately
supervised.

4.2.2 Personal protection equipment shall be used by:

- those doing or otherwise directly involved in the work, AND

- all others who may be at risk from the work.

4.2.3 No personal protection equipment shall be modified without the written authorisation of the manufacturer.

4.2.4 Personal protection equipment shall always be cleaned according to the manufacturer's instructions.

4.2.5 Any personal protection equipment known to have suffered:

- deep scratching,
- visible cracking or distortion,
- significant impact, or
- significant exposure to chemical agents (e.g., paint, adhesives, cleaning agents),

shall be withdrawn from service and repaired or destroyed - whether physical damage is evident or not.

4.2.6 No personal protection equipment shall be used by personnel not adequately trained in the use and care of
such equipment. The training given to users of personal protection equipment shall:

- take proper account of the manufacturer's instructions,

- ensure that the user has been given appropriate hands-on experience and knows:

- the risks which the equipment will avoid or limit,

- the way in which the equipment is to be fitted, used and cared for,
- how to make a proper visual examination of the equipment before use,
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- what action to take if the equipment is suspect, and
- how to return the equipment after use.

4.2.7 For all those given training in the receiving, handling, storing, using, and/or maintenance of personal
protection equipment:

- training shall include initial training and refresher training (where necessary include theoretical
training),
- the frequency and extent of the training shall be appropriate to:

- the type of equipment and its complexity, and

- the frequency with which the worker has the equipment, and
- training records shall be kept.

4.3 Personnel

4.3.1 Those selecting and ordering personal protection equipment shall ensure that they have been given
appropriate training. The importance of making correct decisions at this stage cannot be
overemphasised.

4.3.2 Those receiving, handling & storing personal protection equipment shall ensure that:

- they have been given appropriate training,

- equipment is stored as intended by its manufacturer, adequate to protect it from contamination,
damage (e.g., mechanical damage or damage caused by harmful substances, damp or sunlight) and
loss,
- items received damaged or damaged whilst in their care are reported and taken out of service, and
- that lost items are reported and reordered as necessary.

4.3.3 Those issued with personal protection equipment shall ensure that they:

- have been adequately trained in its use,

- inspect it visually before use, rejecting any equipment considered to be defective,
- make full and proper use of it,
- care for it as instructed, and
- report any damage or loss immediately.

4.3.4 Those maintaining personal protection equipment shall ensure that:

- they are adequately trained to do so,

- the equipment is maintained as intended by its manufacturer, including all appropriate:

- examination,
- cleaning,
- disinfection,
- repair,
- replacement,
- testing, and
- labelling, and

- there is a clear separation and identification of equipment which:

- has been maintained, and

- that which still requires maintenance.

5.0 SPECIFIC TYPES OF EQUIPMENT

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5.1 Head Protection

5.1.1 Industrial safety helmets shall be used by all persons:

- on production, construction or demolition sites,

- in excavations,
- in suspended systems,
- in materials stores, or
- in the immediate vicinity of operating lifting equipment.

5.1.2 In order that head protection is as comfortable as possible, it shall have:

- a flexible, adjustable headband,

- an absorbent, easily replaceable and cleanable sweat-band, and
- textile cradle straps.

5.1.3 Relevant British Standards not listed elsewhere in this specification include:

BSEN 397 Specification for industrial safety helmets.

BSEN 443 Specification for protective helmets for firefighters.

BSEN 812 Specification for industrial scalp protectors (light duty).

5.2 Eye and Face Protection

5.2.1 Eye and face protection shall be used by all persons at possible risk of eye contamination, irritation, impact,
or splashing from :

- flying objects,
- chemicals,
- molten metal,
- liquid droplets, sprays or mists,
- dust,
- hazardous gases and vapours at any pressure,
- all compressed gases and vapours,
- sparks,
- welding arcs,
- non-ionising radiation, or
- the light from lasers.

5.2.2 Persons who normally wear spectacles shall be provide with protection which:

- can be safely and effectively worn over their normal spectacles, or

- can be fitted with prescription lenses (in which case the equipment shall be retained for use by that
person only).

5.2.3 Eye and face protection comes in various forms and it is essential that the form chosen is appropriate to the
risk. For example:

- where the hazard would come from a known direction (e.g., as in welding), faceshields can be
used with normal spectacles and no risk of misting,
- where the hazard could be all around the face (e.g., in handling chlorine), close-fitting goggles are
required (possibly fitted with prescription lenses), and
- in some cases safety spectacles with sideshields will suffice.
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5.2.4 Eye and face protection shall be:

- issued on a personal basis,

- used only be the person to whom it was issued, and
- thoroughly cleaned and disinfected before re-issue.

5.2.5 Relevant British Standards not listed elsewhere in this specification include:

(a) General

BSEN 166 Specification for eye protection for industrial and non-industrial uses.
167 & 168

BSEN 165 Glossary of terms for personal eye protection.

BS 7028 Guide for selection, use and maintenance of eye protection for industrial and other uses.

(b) Special uses

BSEN 208 Specification for personal eye protectors used for adjustment work on lasers and
laser systems.

BSEN 379 Specification for filters with switchable or dual luminous transmittance for
personal eye protectors used in welding and similar operations.

BSEN 175 Specification for equipment for eye, face and neck protection against non-
ionising radiation arising during welding and similar operations.

(c) Filters

BSEN 169 Specification for filters for personal eye protection equipment used in welding
and similar operations.

BSEN 170 Specification for ultraviolet filters used in personal eye protection equipment.

BSEN 171 Specification for Infra-Red Filters used in personal eye protection equipment.

BSEN 172 Specification for sunglare filters used in personal eye protectors for industrial
use.

BSEN 207 Specification for filters and equipment used for personal eye protection against
laser radiation.

(d) Test methods

BSEN 167 Personal eye protection. Optical test methods.

(Partially replaces BS 2092.)

BSEN 168 Personal eye protection. Non-optical test methods.

(Partially replaces BS 2092.)

5.3 Hearing Protection

5.3.1 Hearing protection shall be used by all persons who are exposed to excessive noise cumulatively or over a
long period of time.
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5.3.2 Hearing protection falls into two distinct categories, each with its own advantages and disadvantages as
follows:

- earplugs, which fit inside the ear:

- advantages:
- small and easily carried,
- no interference from headgear, spectacles or hair,
- comfortable in hot environments, and
- do not restrict head movement;
- disadvantages:
- take time to fit,
- protection provided is variable between users,
- risk of infection inside the ear,
- can be worn only in healthy ears; and
- earmuffs (or ear defenders), which fit outside the ear:
- advantages:
- if well-fitting, noise attenuation generally greater than that from earplugs,
- less variable effectiveness between users,
- can be worn despite minor ear infections,
- disadvantages:
- more likely to be ill-fitting,
- uncomfortable in hot environments,
- possible interference from headgear, spectacles and hair, and
- may restrict head movement, especially in confined spaces.

5.3.3 The choice of hearing protection to be provided (i.e. plugs and/or defenders) shall:

- depend on the conditions under which the noise exposure occurs, as well as its characteristics,
frequency distribution, duration and intensity, and
- reduce the noise level to below the recommended limit for unprotected exposure.

5.3.4 Ear defenders and ear plugs may be used together but with little extra protection.

5.3.5 When evaluating the type of ear protection to be provided, it shall be assumed that the worker will wear the
protection continuously in the noisy area. The dangers of failing to use the protection continuously shall be
made fully clear to the worker during training.

5.3.6 Re-usable ear plugs shall NOT be provided as they:

- are less flexible than disposable ear plugs and thus do not generally fit well, and
- require thorough cleaning to avoid the risk of infection.

5.3.7 Earmuffs shall:

- have adjustable spring mechanisms, and

- easily cleaned and replaced seals.

5.3.8 Whenever possible, workers shall be given a choice between ear plugs and ear defenders that provide the
required protection.

5.3.9 Relevant British Standards not listed elsewhere in this specification include:

BSEN 352 Hearing protectors. Safety requirements and testing.

BSEN 458 Hearing protectors. Recommendations for selection, use, care and maintenance.
 GENERAL ENGINEERING SPECIFICATION GES H.11
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BSEN 24869 Acoustics. Hearing protectors.

Pt. 3

BSEN ISO 4869 Acoustics. Hearing protectors.

5.4 Foot Protection

5.4.1 Generally, foot protection shall be:

- tough,
- flexible,
- water resistant,
- permeable and internally absorbent, and
- fitted with slip-resistant, oil-resistant soles, moulded or bonded to the upper.

5.4.2 Foot protection with strong steel toe-caps shall be used by all persons:

- on production, construction or demolition sites,

- in excavations,
- in materials stores, or
- in the immediate vicinity of operating lifting equipment.

5.4.3 Persons working with electrical systems or where there may be flammable atmospheres shall wear anti-
static footwear.

5.4.4 Persons working where there may be chemical spills shall wear footwear which is impermeable and
resistant to attack by those chemicals.

5.4.5 Part of the routine care of protective footwear shall be for the user to remove material lodged into the tread
of the soles.

5.4.6 Relevant British Standards not listed elsewhere in this specification include:

(a) General

BSEN 344-1 Requirements and test methods for safety, protective and occupational footwear for
professional use.

BSEN 345-1 Specification for safety footwear for professional use.

BSEN 346-1 Specification for protective footwear for professional use.

BSEN 347 Specification for occupational footwear for professional use.

BS 5145 Specification for lined industrial vulcanised rubber boots.

BS 6159 Polyvinyl chloride boots.

(b) Special uses

BS 2723 Specification for firemen's leather boots.

5.5 Hand and Arm Protection

5.5.1 Hand and arm protection shall be used by all persons whose work entails significant risk of:
 GENERAL ENGINEERING SPECIFICATION GES H.11
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- cuts or abrasions,
- extreme temperature (particularly if combined with open flame or vibration),
- contact with toxic or corrosive substances,
- electric shock,
- radioactive contamination, or
- infection.

5.5.2 Barrier creams shall not be relied upon as a means of protection against chemicals or infection.

5.5.3 Generally, hand and arm protection shall be tough, flexible, abrasion-resistant, anti-slip, and designed to
maintain an adequate sense of touch.

5.5.4 Special hand and arm protection shall be used for special risks. For example:

- chromed leather shall be used where fire retardance is required,

- neoprene shall be used for handling oils, and
- gloves used for handling toxic liquids shall be selected on the basis of their breakthrough time for
the liquid concerned.

5.5.5 Despite the use of hand and arm protection:

- during work:

- any cuts or abrasions shall be covered with waterproof plasters, and

- after work:

- hands and arms shall be thoroughly washed and dried,

- waterproof plasters shall be changed for porous ones, and
- if necessary, hand cream shall be used to keep the skin from becoming dry through loss
of natural oils.

5.5.6 Relevant British Standards not listed elsewhere in this specification include:

(a) General

BSEN 388 Protective gloves against mechanical risks.

BSEN 420 General requirements for gloves.

(b) Special uses

BSEN 374 Protective gloves against chemicals and micro-organisms.

BSEN 407 Protective gloves against thermal risks (heat and/or fire).

BSEN 421 Protective gloves against ionising radiation and radioactive contamination.

BSEN 60903 Specification for gloves and mitts of insulating material for live working.

IEC 60903 Specification for rubber gloves for electrical purposes.

5.6 Body Protection

5.6.1 Body protection shall be used by all persons:

- on production, construction or demolition sites,

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- in materials stores, or
- in laboratories.

5.6.2 The minimum level of body protection shall be tough, fire retardant clothing which covers body, legs,
shoulders and upper arms. Long sleeved garments are preferred.

5.6.3 Special body clothing shall be worn for persons subject to special risks, such as:

- firefighters (who require fire resistant and fire entry suits),

- road traffic controllers (who require high visibility clothing),
- chemicals and solvents handling, and
- hazardous dust/particle operations.

5.6.4 Special body clothing shall be used only for the special purpose for which it was designed.

5.6.5 Relevant British Standards not listed elsewhere in this specification include:

(a) General

BSEN 340 Protective clothing. General requirements.

BSEN 510 Specification for protective clothing for use where there is a risk of entanglement with
moving arts.

BSEN 531 Protective clothing for industrial workers exposed to heat (excluding Fire-Fighters and
Welders clothing).

BS 1771 Fabrics for uniforms and workwear.

Pts. 1 & 2

BS 5426 Specification for workwear and career wear.

BSEN 533 Materials and material assemblies used in clothing for protection against heat and flame.

(b) Special uses

BSEN 348 Protective clothing. Determination of behaviour of materials on impact of small splashes
of molten metal.

BSEN 412 Specification for protective aprons for use with hand knives.

BSEN 465 Protective clothing. Protection against liquid chemicals. Performance requirements for
chemical protective clothing with spray-tight connections between different parts of the
clothing.

BSEN 466 Protective clothing. Protection against liquid chemicals. Performance requirements for
chemical protective clothing with liquid-tight connections between different parts of the
clothing.

BSEN 467 Protective clothing. Protection against liquid chemicals. Performance requirements for
garments providing protection to parts of the body.

BSEN 469 Protective clothing for firefighters. Requirements and test methods for protective clothing
for firefighting.

BSEN 470 Pt 1 Protective clothing for use in welding and allied processes - General Requirements.
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BSEN 471 Specification for high visibility warning clothing.

(c) Test methods

BSEN 366 Protective clothing. Protection against heat and fire.

Method of test: evaluation of materials and material assemblies when exposed to a source
of radiant heat.

BSEN 367 Protective clothing. Protection against heat and fire. Method for determining heat
transmission on exposure to flame.

BSEN 368 Protective clothing. Protection against liquid chemicals. Test method: resistance of
materials to penetration by liquids.

BSEN 369 Protective clothing. Protection against liquid chemicals. Test method: resistance of
materials to permeation by liquids.

BSEN 373 Protective clothing. Assessment of resistance of materials to molten metal splash.

BSEN 463 Protective clothing. Protection against liquid chemicals. Test method: determination of
resistance to penetration by a jet of liquid.

BSEN 464 Protective clothing. Protection against liquid and gaseous chemicals, including liquid
aerosols and solid particles.
Test Method: determination of leak-tightness of gas-tight suits. (Internal Pressure Tests)

BSEN 468 Protective clothing for use against liquid chemicals.

Test Method: determination of resistance to penetration by spray.

BSEN 532 Protective clothing. Protection against heat and flame.

Test method for limited flame spread.

BSEN 702 Protective clothing. Protection against heat and flame.

Test method: determination of the contact heat transmission through protective clothing
or its materials.

5.7 Safety Belts, Harnesses and Lines

5.7.1 Safety lines and harnesses shall be used by all persons whose work entails significant risk of falling from a
height. For example, persons:

- working on the construction of structural frames,

- climbing on towers and masts,
- cleaning windows at height,
- working suspended inside confined spaces (e.g., storage tanks, furnaces and process vessels),
- working in deep pits, or
- working on the monkey board during drilling operations.

5.7.2 The protection equipment provided shall:

- be strong, light-weight, and suitable for the local environment (with non-corrosive metal parts),
- reduce the risk of falling, and
- in the event of a fall:
- catch the wearer smoothly, and
- limit the distance fallen.

5.7.3 Preference shall be given to systems which spread the forces arising from the fall over the trunk, legs, and
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arms and thus minimise the internal and external injury suffered.

5.7.4 To avoid injury due to sudden deceleration, the maximum free fall shall be 2 feet (600 mm) unless some
form of shock absorber or decelerating device is incorporated. For a fall of up to 5 feet (1500 mm),
synthetic fibre rope provides adequate shock absorption. Chain, cable or natural fibre rope shall not be used
unless shock absorbing properties re built into the belt or harness. Friction reel or inertia devices are
acceptable provided that particularly close attention is paid to their proper use and maintenance.

5.7.5 For work in confined spaces, the system provided shall be designed to facilitate rescue of the suspended
worker in the event that he loses consciousness (e.g., due to fumes or oxygen deficiency).

5.7.6 To overcome the restriction of movement caused by the use of the equipment, where safe to do so it is
permitted to use a harness hook attached to an overhead horizontal cable designed for that purpose.

5.7.7 In the event that a safety belt, harness or line has been used to arrest a fall, the equipment shall be fully
tested and recertified before being used again.
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5.7.8 Relevant British Standards not listed elsewhere in this specification include:

(a) General

Personal protective equipment against falls from a height:

BSEN 341 Descender devices.

BSEN 353 Guided type fall arrestors.

BSEN 354 Lanyards.

BSEN 355 Energy absorbers.

BSEN 360 Retractable type fall arresters.

BSEN 361 Full body harnesses.

BSEN 362 Connectors.

BSEN 363 Fall arrest systems.

BSEN 365 General requirements for instructions for use and for marking.

BSEN 358 Personal protective equipment for work positioning and prevention of falls from a height.
Work positioning systems.

(b) Special uses

BS 3367 Specification for fire brigade & industrial ropes and rescue lines.

(c) Test methods

BSEN 364 Test methods.

5.8 Life Jackets and Buoyancy Aids

5.8.1 Life jackets shall be used by all persons who run a foreseeable risk of drowning when working over water.

5.8.2 A life jacket shall provide sufficient buoyancy to turn face upwards and support an unconscious person:

- with his mouth and nose well clear of the water, and
- within five seconds if non-inflatable type, and ten seconds if inflatable type.

5.8.3 Buoyancy aids (which only provide extra buoyancy to assist a conscious person to keep afloat and do not
turn over an unconscious person from a face down position) shall be used only when the use of a life
jacket would result in a higher level of risk to the wearer.

5.8.4 Relevant British Standards not listed elsewhere in this specification include:

Lifejackets and personal buoyancy aids:

BSEN 393 Buoyancy aid 50.

BSEN 394 Additional items.

BSEN 395 Lifejacket 100.

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BSEN 396 Lifejacket 150.

BSEN 399 Lifejacket 275.

5.9 Breathing Protection

5.9.1 Breathing (or respiratory) protection shall be used by all persons who run a foreseeable risk of:

- breathing in harmful substances:

- dusts, mists, particulates, or micro-organisms, or
- gases or vapours, or
- suffering from oxygen deficiency,

for example where:

- exposures exceed the appropriate occupational exposure limits,
- maintenance is required in high contamination areas, or
- emergency escape with portable air supply may be required.

5.9.2 All respiratory protection shall be capable of providing a sufficient quantity of clean air for the wearer to
breathe without difficulty.

5.9.3 As not all models will fit all sizes and shapes of face, a range of equipment for each type of service shall
always be held in stock.

5.9.4 Respiratory protection falls essentially into two categories:

- equipment which has limited use such as (i) face masks with filters and (ii) powered respirators
which both take in contaminated air from the work space and filter or clean it before it is inhaled
(all such devices being termed 'respirators'), and
- equipment which can be used against any form of non-radioactive contaminant such as (i) air-fed
hoods and (ii) self-contained breathing apparatus which both deliver uncontaminated air to the
wearer from an independent source.
Within these two categories there are further important sub-divisions, there being about 30 different types
in all.

5.9.5 For protection against harmful substances using a respirator, the exact choice of respirator shall be made for
the specific risk in close consultation with the manufacturer, taking into account such factors as:

- toxicity,
- particle size,
- chemical characteristics, and
- breakthrough level (when the filter becomes saturated and the hazardous substance passes straight
through it).

5.9.6 Respirators:

- shall be provided appropriately for low levels of harmful dust,

- SHALL NOT be used where there is any risk of loss of consciousness or asphyxiation.

5.9.7 Breathing air supplied to workers shall:

- contain not more than:

- 5 parts per million (ppm) by volume of carbon monoxide, or
- 500 ppm of carbon dioxide,
- have no oil odour,
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- be supplied at:
- a temperature of 15 - 20 deg.C,
- a maximum relative humidity of 85% with no condensed water, and
- a minimum flow rate of 120 litres per minute per person.

5.9.8 Positive pressure self-contained compressed air breathing apparatus shall be provided for all work in
atmospheres which are immediately dangerous to life or health, including:

- underwater work,
- firefighting, and
- work in toxic or oxygen-deficient atmospheres.

5.9.9 Escape breathing apparatus shall not be used for normal working or entry into a danger area.

5.9.10 Fresh air hose systems (incorporating a compressor as appropriate) shall be provided for extended duration
activities requiring respiratory protection.

5.9.11 Hose for fresh air equipment shall be strong, flexible and crush- and kink-resistant.

5.9.12 Closed-circuit self-contained breathing apparatus using oxygen shall not be provided at all, for the
following reasons:

a) The presence of oxygen in the atmosphere in a concentration higher than normal will increase the
rate of any combustion.

b) Oxygen may spontaneously react with oils, greases or dirt.

5.9.13 Whenever respiratory protection is being selected for a specific task, appropriate arrangements for essential
communications shall be incorporated.

5.9.14 Those needing to use any form of respiratory protection shall be given specific training with the equipment
which they will use to familiarise them with:

- the correct operating procedure,

- the extra breathing resistance imposed on the lungs,
- the restricted mobility and visibility, and
- the weight of the equipment.

5.9.15 In addition, those needing to wear positive pressure breathing apparatus shall be made fully aware that
anything which adversely affects the seal of the mask against the face (e.g., beards and spectacles) will
significantly reduce their level of safety.

5.9.16 For all work in atmospheres which are immediately dangerous to life or health, workers shall be
continuously supervised from outside the danger area, with appropriate communications and rescue
facilities always available.

5.9.17 All respiratory protection equipment shall be cleaned and disinfected after each use.
5.9.18 Relevant British Standards not listed elsewhere in this specification include:

(a) General

Respiratory protective devices:

BSEN 132 Definitions.

BSEN 133 Classification.

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BSEN 134 Nomenclature of components.

BSEN 135 List of equivalent terms.

BS 4275 Recommendations for the selection, use and maintenance of respiratory protective
equipment.

(b) Fresh air

BSEN 138 Respiratory protective devices. Specification for fresh air hose breathing apparatus for
use with full face mask, half mask or mouthpiece assembly - Requirements Testing
marking.

BSEN 269 Respiratory protective devices. Powered fresh air hose breathing apparatus incorporating
a hood.

(c) Compressed air

BSEN 137 Specification for respiratory protective devices:

Self-contained open-circuit compressed air breathing apparatus.

BSEN 139 Respiratory protective devices. Compressed air line breathing apparatus for use with a
full face mask, half mask or a mouthpiece assembly.

BSEN 250 Respiratory equipment. Open-circuit self-contained compressed air diving apparatus.

BSEN 270 Respiratory protective devices. Compressed air line breathing apparatus incorporating a
hood.

BSEN 271 Respiratory protective devices. Compressed air line or powered fresh air hose breathing
apparatus incorporating a hood for use in abrasive blasting operations.

BS 4001 Care and maintenance of underwater breathing apparatus.

(d) Oxygen

BSEN 145 Respiratory protective devices. Self-contained closed-circuit breathing apparatus or

compressed oxygen-nitrogen type.

BSEN 145 Specification for respiratory protective devices. Self-contained closed-circuit compressed
oxygen breathing apparatus.
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(e) Self-rescue

Respiratory protective devices for self-rescue:

BSEN 400 Self-contained closed-circuit breathing apparatus.

Compressed oxygen escape apparatus.

BSEN 401 Self-contained closed-circuit breathing apparatus. Chemical oxygen (KO2) escape
apparatus.

BSEN 402 Self-contained open-circuit compressed air breathing apparatus with full face mask or
mouthpiece assembly.

BSEN 404 Filter self-rescuer.

BSEN 403 Specification for filtering respiratory protective devices with hood for self-rescue from
fire.

BSEN 1146 Breathing Apparatus specification for open-circuit escape breathing apparatus.

(f) Components

Masks and facepieces

BSEN 136 Requirements Testing Marking - Respiratory protective devices - Full Face Masks.

BSEN 148 Pt. 3 Respiratory protective devices. Threads for facepieces.

BS 7156 Respiratory protective devices. Threads for facepieces.

BS 7309 Specification for mouthpiece assemblies for respiratory protective devices.

BSEN 136 Requirements Testing Marking - Respiratory Protective Devices - Full Face Masks.

BS 7356 Specification for half masks and quarter masks for respiratory protective devices.

Filters

BSEN 141 Respiratory Protective Devices - Gas filters & Combined Filters

BSEN 143 Respiratory Protective Devices - Particle Filters.

BSEN 146 Respiratory protective devices - Particle Filtering devices incorporating helmets or hoods
-Requirements, Testing, Marking.

BSEN 147 Respiratory protective devices. Power assisted particle filtering devices incorporating
full face masks, half masks or quarter masks - Requirements, Testing, Marking.

BSEN 149 Respiratory Protective Devices - filtering half masks to protect against particles -
Requirement, Testing, Marking.
BSEN 372 Specification for SX gas filters and combined filters against specific named compounds
used in respiratory protective equipment.

BSEN 405 Respiratory protective devices. Valved filtering half-masks to protect against gases or
gases and particles - Requirements, Testing, Marking.
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BS 4400 Method for sodium chloride particulate test for respirator filters.

Cylinders and valves

BSEN 144 Pt 1 Respiratory protective devices. Gas cylinder valves.

6.0 EQUIPMENT PURCHASE

6.1 Design and Construction

6.1.1 Only personal protection equipment which has been type approved by a recognised authority shall be
provided.

6.1.2 Only certified materials shall be used for pressure containing systems.

6.1.3 All painting and coating shall be adequate for the intended service.

6.2 Inspection and Testing

6.2.1 Protective clothing and BA sets will usually be off-the-shelf standard items and, as such, shall be strictly
controlled by the manufacturer's quality control systems.

6.2.2 The Vendor/Contractor always has the responsibility to provide adequate Quality control and inspection of
equipment and materials. Any inspection by Owner or his Inspector shall not relieve the Vendor/Contractor
of these responsibilities or those under his guarantees.

6.2.3 All equipment and materials shall be tested in accordance with the manufacturer's standard procedures prior
to leaving the Vendor's/Contractor's factory.

6.2.4 If so specified on the Purchase Order/Contract, selected testing shall be carried out in the presence of the
Owner's Inspector.

6.2.5 The results of all tests performed shall be recorded on signed test certificates.

6.2.6 The Vendor/Contractor shall provide all consumables, personnel and the site, systems and equipment
required for testing.

6.3 Documentation

6.3.1 Where operation and maintenance manuals are required, these shall be:

- provided six-fold in Arabic and English.

- checked for completeness by the inspector.

6.3.2 All equipment and materials shall be fully documented and changes to any document shall be recorded by
changing the document index.

6.3.3 The detailed list of documents that are required is attached to the Purchase Order/Contract.

6.4 Spares

For equipment requiring spare parts, the Vendor/Contractor shall submit with his proposal a list of
recommended spares for two years operation for review by the Owner.

6.5 Packing and Shipping

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6.5.1 Before shipment, all equipment and materials shall be inspected for compliance with the Purchase
Order/Contract.

6.5.2 The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24 months
shall be assumed.

6.5.3 The following preparation for shipment shall be a minimum requirement:

- after completion at the works, all equipment supplied to this specification shall be left in a clean
dry condition, and
- the Vendor/Contractor shall be responsible for packing the equipment and materials to prevent
damage during shipment.

6.5.4 Detailed shipping arrangements are covered by the Contract and the Purchase Order/Contract.

6.6 Warranty

6.6.1 The Vendor/Contractor shall warrant all materials and services supplied against any defect for a minimum
of 12 months after release or for the period stipulated in the order, whichever is the longer.

6.6.2 Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.11

PROTECTIVE CLOTHING AND BA SETS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES H.11
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INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Assessing Requirements 6

4.0 GENERAL USE, CARE AND MAINTENANCE OF EQUIPMENT 7

4.1 General 7
4.2 Procedures 7
4.3 Personnel Training 8

5.0 SPECIFIC TYPES OF EQUIPMENT 9

5.1 Head Protection 9

5.2 Eye and Face Protection 9
5.3 Hearing Protection 11
5.4 Foot Protection 12
5.5 Hand and Arm Protection 13
5.6 Body Protection 14
5.7 Safety Belts, Harnesses and Lines 16
5.8 Life Jackets and Buoyancy Aids 17
5.9 Breathing Protection 18

6.0 EQUIPMENT PURCHASE 22

6.1 Design and Construction 22

7.0 INSPECTION AND TESTING 22

7.1 Inspection 22
7.2 Testing 22
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INDEX

SEC TITLE PAGE

8.0 DOCUMENTATION 23

8.1 Introduction 23
8.2 Schedules and Reports 23
8.3 Data and Calculations 23
8.4 Drawings 24
8.5 Final Records, Documents and Manuals 24

9.0 PRIOR TO SHIPMENT 25

9.1 Painting and Coatings 25

9.2 Spares 25
9.3 Packing and Storage 25
9.4 Shipping 25
9.5 Warranty 25
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification defines the minimum requirements for protective clothing and breathing apparatus (BA)
sets.

1.1.2 This specification applies to protective clothing and BA sets for refineries, onshore oil and gas installations,
and processing facilities.

1.1.3 This specification does not cover:

- ordinary clothes and uniforms provided for the primary purpose of presenting a corporate image;
- portable devices for detecting and signalling risks (e.g. personal gas detectors or radiation
dosimeters);
- protective equipment for protection for radio-active hazards, road travel, kitchen hygiene, or
sports.

1.1.4 The provision of protective clothing and BA sets shall be based upon the following:

a) Personal protection equipment shall be provided at all places of employment to ensure the
adequate and appropriate provision of personal protection where this cannot be achieved by better
means.

b) The provision of personal protection equipment shall be treated as the last resort to minimise risks
and shall not be considered as a substitute for best possible engineering controls and safe working
procedures, which shall always be developed first.

c) When comparing the protection provided by personal protection equipment with that provided by
good engineered controls and safe working procedures, full account shall be taken of the
following:

- personal protection equipment protects only the individual wearing it;

- its effectiveness is difficult to assess and dependant on it being used properly and
consistently.

d) Throughout this specification, details of relevant British Standards have been included for entry
into Purchase Order/Contract and operating procedures as appropriate. The inclusion of this
information is not intended to be restrictive.

1.1.5 This General Engineering Specification will form part of the Purchase Order/Contract together with any
Data Sheets, drawings or other documents.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES A.04 Noise Level Criteria and Noise Control

GES H.02 Safety Signs and their Applications

GES H.09 Emergency Shower and Eyewash Facilities

2.0 DEFINITIONS
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2.1 Technical

The technical terms used in this specification are defined as follows:

Protective clothing

The term protective clothing shall mean all clothing and personal equipment which is intended to be worn
or held by personnel at work to protect them against risk to their health or safety in the performance of their
work duties.

BA Set

A system which permits the wearer to carry a limited supply of breathable air with him into a hazardous or
potentially hazardous location.

Personal Protection Equipment

Within the context of this specification, personal protection equipment (PPE) shall mean all protective
clothing and BA sets which fall within its scope.

Hazard

The potential to cause harm to personnel and damage to properties.

Consequence

The likely severity of harm to personnel and damage to properties from a particular hazard.

Frequency

The likelihood that a particular hazard will occur.

Risk

A multiple of consequence and frequency, a high risk thus incorporating a high likely severity and a high
likelihood of occurrence.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.
 GENERAL ENGINEERING SPECIFICATION GES H.11
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Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

In view of the large number of standards dealing with protective clothing and BA Sets, relevant British
Standards have been included in Section 5.0 under specific equipment headings.

3.2 Assessing Requirements

3.2.1 In assessing the required level of personal protection equipment to be provided at a given location as a
whole, the following shall be considered:

- the workplace hazards and risks, particularly those presented by:

- hazardous materials;
- new constructions;
- non-routine activities;
- dangerous machinery;
- the numbers, types and geographical distribution of people usually present;
- the needs of travelling and remote workers and night shift workers;
- accident history at the location (number, type, frequency and severity);
- the remoteness of the location from back-up support.

3.2.2 In assessing the personal protection equipment to be provided for a given task, the following shall be
considered:

- the nature of the task;

- the physical effort required to do the task;
- the methods of work;
- requirements for mobility, visibility and communication.

3.2.3 The personal protection equipment provided to an individual shall:

- be appropriate for the risks involved;

- take account of ergonomic requirements;
- SHALL NOT increase the overall risk to him.

3.2.4 Dependant only on the risks associated with the work to be done, personal protection equipment shall be
equally available to all persons on the premises who may be exposed to a risk to their health or safety
whilst on the premises, regardless of whether they are employees, contractors, visitors or others, (which
shall not in any way indicate any legal liability).

3.2.5 Personal protection equipment shall be provided without charge to the worker required to use it.
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3.2.6 All persons required to use personal protection equipment shall be adequately instructed in its use and care,
with no charge for such instruction.

3.2.7 Where personal protection equipment is required, there shall be a reliable system in place for its training,
provision, storage, distribution, inspection, maintenance and replacement.

3.2.8 Personal protection equipment provided at each location shall be re-assessed at least every three (3) years
(or more frequently if required by legislation), and before any significant change in the activities at the
location.

4.0 GENERAL USE, CARE AND MAINTENANCE OF EQUIPMENT

4.1 General

4.1.1 All personal protection equipment shall be:

- designed, constructed, tested and approved to a recognised standard;

- suitably marked in Arabic and English;
- easily accessible;
- in good order at all times;
- used only by those trained to do so.

4.1.2 The Company's Hazardous Materials Manual shall be used as the base document when assessing the
personal protection equipment required to work with a specific hazardous material.

4.2 Procedures

4.2.1 The use, care and maintenance of personal protection equipment shall be appropriately and adequately
supervised.

4.2.2 Personal protection equipment shall be used by:

- those doing or otherwise directly involved in the work;

- all others who may be at risk from the work.

4.2.3 No personal protection equipment shall be modified without the written authorisation of the manufacturer.

4.2.4 Personal protection equipment shall always be cleaned according to the manufacturer's instructions.

4.2.5 Any personal protection equipment known to have suffered:

- deep scratching;
- visible cracking or distortion;
- significant impact;

- significant exposure to chemical agents (e.g. paint, adhesives, cleaning agents).

shall be withdrawn from service and repaired or destroyed - whether physical damage is evident or not.

4.2.6 No personal protection equipment shall be used by personnel not adequately trained in the use and care of
such equipment. The training given to users of personal protection equipment shall:

- take proper account of the manufacturer's instructions;

- ensure that the user has been given appropriate hands-on experience and knows:
- the risks which the equipment will avoid or limit;
- the way in which the equipment is to be fitted, used and cared for;
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- how to make a proper visual examination of the equipment before use;
- what action to take if the equipment is suspect;
- how to return the equipment after use.

4.2.7 For all those given training in the receiving, handling, storing, using, and/or maintenance of personal
protection equipment:

- training shall include initial training and refresher training (where necessary include theoretical
training);
- the frequency and extent of the training shall be appropriate to:
- the type of equipment and its complexity;
- the frequency with which the worker has the equipment;
- training records shall be kept.

4.3 Personnel Training

4.3.1 Those selecting and ordering personal protection equipment shall ensure that they have been given
appropriate training. The importance of making correct decisions at this stage cannot be
overemphasised.

4.3.2 Those receiving, handling & storing personal protection equipment shall ensure that:

- they have been given appropriate training;

- equipment is stored as intended by its manufacturer, adequate to protect it from contamination,
damage (e.g. mechanical damage or damage caused by harmful substances, damp or sunlight) and
loss;
- items received damaged or damaged whilst in their care are reported and taken out of service;
- that lost items are reported and reordered as necessary.

4.3.3 Those issued with personal protection equipment shall ensure that they:

- have been adequately trained in its use;

- inspect it visually before use, rejecting any equipment considered to be defective;
- make full and proper use of it;
- care for it as instructed;
- report any damage or loss immediately.

4.3.4 Those maintaining personal protection equipment shall ensure that:

- they are adequately trained to do so;

- the equipment is maintained as intended by its manufacturer, including all appropriate:
- examination;
- cleaning;
- disinfection;
- repair;
- replacement;
- testing;
- labelling.

4.3.5 Those maintaining personal protection equipment shall ensure that:

- there is a clear separation and identification of equipment which:

- has been maintained;
- that which still requires maintenance.

5.0 SPECIFIC TYPES OF EQUIPMENT

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5.1 Head Protection

5.1.1 Industrial safety helmets shall be used by all persons:

- on production, construction or demolition sites;

- in excavations;
- in suspended systems;
- in materials stores;
- in the immediate vicinity of operating lifting equipment.

5.1.2 In order that head protection is as comfortable as possible, it shall have:

- a flexible, adjustable headband;

- an absorbent, easily replaceable and cleanable sweat-band;
- textile cradle straps.

5.1.3 Relevant British Standards not listed elsewhere in this specification include:

BSEN 397 Specification for industrial safety helmets.

BSEN 443 Specification for protective helmets for firefighters.

BSEN 812 Specification for industrial scalp protectors (light duty).

5.2 Eye and Face Protection

5.2.1 Eye and face protection shall be used by all persons at possible risk of eye contamination, irritation, impact,
or splashing from:

- flying objects;
- chemicals;
- molten metal;
- liquid droplets, sprays or mists;
- dust;
- hazardous gases and vapours at any pressure;
- all compressed gases and vapours;
- sparks;
- welding arcs;
- non-ionising radiation;
- the light from lasers.

5.2.2 Persons who normally wear spectacles shall be provide with protection which:

- can be safely and effectively worn over their normal spectacles;

- can be fitted with prescription lenses (in which case the equipment shall be retained for use by that
person only).

5.2.3 Eye and face protection comes in various forms and it is essential that the form chosen is appropriate to the
risk. For example:

- where the hazard would come from a known direction (e.g. as in welding), faceshields can be used
with normal spectacles with no risk of misting;
- where the hazard could be all around the face (e.g. in handling chlorine), close-fitting goggles are
required (possibly fitted with prescription lenses);
- in some cases safety spectacles with sideshields will suffice.
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5.2.4 Eye and face protection shall be:

- issued on a personal basis;

- used only be the person to whom it was issued;
- thoroughly cleaned and disinfected before re-issue.

5.2.5 Relevant British Standards not listed elsewhere in this specification include:

(a) General

BSEN 165 Personal eye protection - Vocabulary

BSEN 166 Personal eye-protection - Specifications.

BS 7028 Guide for selection, use and maintenance of eye protection for industrial and other uses.

(b) Special uses

BSEN 208 Personal eye-protections - eye-protectors for adjustment work on lasers and laser
systems (laser adjustment eye-protectors).

BSEN 379 Specification for filters with switchable or dual luminous transmittance for
personal eye-protectors used in welding and similar operations.

BSEN 175 Specification for equipment for eye, face and neck protection against non-
ionising radiation arising during welding and similar operations.

(c) Filters

BSEN 169 Specification for filters for personal eye protection equipment used in welding
and similar operations.

BSEN 170 Specification for ultraviolet filters used in personal eye protection equipment.

BSEN 171 Specification for Infra-Red Filters used in personal eye protection equipment.

BSEN 172 Specification for sunglare filters used in personal eye protectors for industrial
use.

BSEN 207 Personal eye protection - filters and eye-protectors against laser radiation (laser
eye-protectors).

(d) Test methods

BSEN 167 Personal eye protection. Optical test methods.

BSEN 168 Personal eye protection. Non-optical test methods.

5.3 Hearing Protection

5.3.1 Hearing protection shall be used by all persons who are exposed to excessive noise cumulatively or over a
long period of time.

5.3.2 Hearing protection falls into two distinct categories, each with its own advantages and disadvantages as
follows:

- earplugs, which fit inside the ear:

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advantages:
- small and easily carried;
- no interference from headgear, spectacles or hair;
- comfortable in hot environments;
- do not restrict head movement.
disadvantages:
- take time to fit;
- protection provided is variable between users;
- risk of infection inside the ear;
- can be worn only in healthy ears.
- earmuffs (or ear defenders), which fit outside the ear:
advantages:
- if well-fitting, noise attenuation generally greater than that from earplugs;
- less variable effectiveness between users;
- can be worn despite minor ear infections.
disadvantages:
- more likely to be ill-fitting;
- uncomfortable in hot environments;
- possible interference from headgear, spectacles and hair;
- may restrict head movement, especially in confined spaces.

5.3.3 The choice of hearing protection to be provided (i.e. plugs and/or defenders) shall:

- depend on the conditions under which the noise exposure occurs, as well as its characteristics,
frequency distribution, duration and intensity;
- reduce the noise level to below the recommended limit for unprotected exposure.

5.3.4 Ear defenders and ear plugs may be used together but joint use provides little extra protection.

5.3.5 When evaluating the type of ear protection to be provided, it shall be assumed that the worker will wear the
protection continuously in the noisy area. The dangers of failing to use the protection continuously shall be
made fully clear to the worker during training.

5.3.6 Re-usable ear plugs shall NOT be provided as they:

- are less flexible than disposable ear plugs and thus do not generally fit well;
- require thorough cleaning to avoid the risk of infection.

5.3.7 Earmuffs shall:

- have adjustable spring mechanisms;

- be easily cleaned and replaced seals.

5.3.8 Whenever possible, workers shall be given a choice between ear plugs and ear defenders that provide the
required protection.

5.3.9 Relevant British Standards not listed elsewhere in this specification include:

BSEN 352 Hearing protectors. Safety requirements and testing.

BSEN 458 Hearing protectors. Recommendations for selection, use, care and maintenance.

BSEN 24869 Acoustics. Hearing protectors.

Pt. 3
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BSEN ISO 4869 Acoustics. Hearing protectors.

5.4 Foot Protection

5.4.1 Generally, foot protection shall be:

- tough;
- flexible;
- water resistant;
- permeable and internally absorbent;
- fitted with slip-resistant, oil-resistant soles, moulded or bonded to the upper.

5.4.2 Foot protection with strong steel toe-caps shall be used by all persons:

- on production, construction or demolition sites;

- in excavations;
- in materials stores;
- in the immediate vicinity of operating lifting equipment.

5.4.3 Persons working with electrical systems or where there may be flammable atmospheres shall wear anti-
static footwear.

5.4.4 Persons working where there may be chemical spills shall wear footwear which is impermeable and
resistant to attack by those chemicals.

5.4.5 Part of the routine care of protective footwear shall be for the user to remove material lodged into the tread
of the soles.
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5.4.6 Relevant British Standards not listed elsewhere in this specification include:

(a) General

BSEN 344-1 Requirements and test methods for safety, protective and occupational footwear for
professional use.

BSEN 345-1 Specification for safety footwear for professional use.

BSEN 346-1 Specification for protective footwear for professional use.

BSEN 347 Specification for occupational footwear for professional use.

BS 5145 Specification for lined industrial vulcanised rubber boots.

BS 6159 Polyvinyl chloride boots.

(b) Special uses

BS 2723 Specification for firemen's leather boots.

5.5 Hand and Arm Protection

5.5.1 Hand and arm protection shall be used by all persons whose work entails significant risk of:

- cuts or abrasions;
- extreme temperature (particularly if combined with open flame or vibration);
- contact with toxic or corrosive substances;
- electric shock;
- radioactive contamination;
- infection.

5.5.2 Barrier creams shall not be relied upon as a means of protection against chemicals or infection.

5.5.3 Generally, hand and arm protection shall be tough, flexible, abrasion-resistant, anti-slip, and designed to
maintain an adequate sense of touch.

5.5.4 Special hand and arm protection shall be used for special risks. For example:

- chromed leather shall be used where fire retardance is required;

- neoprene shall be used for handling oils;
- gloves used for handling toxic liquids shall be selected on the basis of their breakthrough time for
the liquid concerned.

5.5.5 Despite the use of hand and arm protection:

- during work:
- any cuts or abrasions shall be covered with waterproof plasters.

- after work:
- hands and arms shall be thoroughly washed and dried;
- waterproof plasters shall be changed for porous ones;
- if necessary, hand cream shall be used to keep the skin from becoming dry through loss
of natural oils.

5.5.6 Relevant British Standards not listed elsewhere in this specification include:
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(a) General

BSEN 388 Protective gloves against mechanical risks.

BSEN 420 General requirements for gloves.

(b) Special uses

BSEN 374 Protective gloves against chemicals and micro-organisms.

BSEN 407 Protective gloves against thermal risks (heat and/or fire).

BSEN 421 Protective gloves against ionising radiation and radioactive contamination.

BSEN 60903 Specification for gloves and mitts of insulating material for live working.

IEC 60903 Specification for rubber gloves for electrical purposes.

5.6 Body Protection

5.6.1 Body protection shall be used by all persons:

- on production, construction or demolition sites;

- in materials stores;
- in laboratories.

5.6.2 The minimum level of body protection shall be tough, fire retardant clothing which covers body, legs,
shoulders and upper arms. Long sleeved garments are preferred.

5.6.3 Special body clothing shall be worn for persons subject to special risks, such as:

- firefighters (who require fire resistant and fire entry suits);

- road traffic controllers (who require high visibility clothing);
- chemicals and solvents handling;
- hazardous dust/particle operations.

5.6.4 Special body clothing shall be used only for the special purpose for which it was designed.

5.6.5 Relevant British Standards not listed elsewhere in this specification include:

(a) General

BSEN 340 Protective clothing. General requirements.

BSEN 510 Specification for protective clothing for use where there is a risk of entanglement with
moving arts.

BSEN 531 Protective clothing for industrial workers exposed to heat (excluding Fire-Fighters and
Welders clothing).

BS 1771 Fabrics for uniforms and workwear.

Pts. 1 & 2

BS 5426 Specification for workwear and career wear.

BSEN 533 Materials and material assemblies used in clothing for protection against heat and flame.
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(b) Special uses

BSEN 348 Protective clothing. Determination of behaviour of materials on impact of small splashes
of molten metal.

BSEN 412 Specification for protective aprons for use with hand knives.

BSEN 465 Protective clothing. Protection against liquid chemicals. Performance requirements for
chemical protective clothing with spray-tight connections between different parts of the
clothing.

BSEN 466 Protective clothing. Protection against liquid chemicals. Performance requirements for
chemical protective clothing with liquid-tight connections between different parts of the
clothing.

BSEN 467 Protective clothing. Protection against liquid chemicals. Performance requirements for
garments providing protection to parts of the body.

BSEN 469 Protective clothing for firefighters. Requirements and test methods for protective clothing
for firefighting.

BSEN 470 Pt 1 Protective clothing for use in welding and allied processes - General Requirements.

BSEN 471 Specification for high visibility warning clothing.

(c) Test methods

BSEN 366 Protective clothing. Protection against heat and fire.

Method of test: evaluation of materials and material assemblies when exposed to a source
of radiant heat.

BSEN 367 Protective clothing. Protection against heat and fire. Method for determining heat
transmission on exposure to flame.

BSEN 368 Protective clothing. Protection against liquid chemicals. Test method: resistance of
materials to penetration by liquids.

BSEN 369 Protective clothing. Protection against liquid chemicals. Test method: resistance of
materials to permeation by liquids.

BSEN 373 Protective clothing. Assessment of resistance of materials to molten metal splash.

BSEN 463 Protective clothing. Protection against liquid chemicals. Test method: determination of
resistance to penetration by a jet of liquid.

BSEN 464 Protective clothing. Protection against liquid and gaseous chemicals, including liquid
aerosols and solid particles.
Test Method: determination of leak-tightness of gas-tight suits. (Internal Pressure Tests)

BSEN 468 Protective clothing for use against liquid chemicals.

Test Method: determination of resistance to penetration by spray.

BSEN 532 Protective clothing. Protection against heat and flame.

Test method for limited flame spread.

BSEN 702 Protective clothing. Protection against heat and flame.

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Test method: determination of the contact heat transmission through protective clothing
or its materials.

5.7 Safety Belts, Harnesses and Lines

5.7.1 Safety lines and harnesses shall be used by all persons whose work entails significant risk of falling from a
height. For example, persons:

- working on the construction of structural frames;

- climbing on towers and masts;
- cleaning windows at height;
- working suspended inside confined spaces (e.g. storage tanks, furnaces and process vessels);
- working in deep pits;
- working on the monkey board during drilling operations.

5.7.2 The protection equipment provided shall:

- be strong, light-weight, and suitable for the local environment (with non-corrosive metal parts);
- reduce the risk of falling;
- in the event of a fall:
- catch the wearer smoothly;
- limit the distance fallen.

5.7.3 Preference shall be given to systems which spread the forces arising from the fall over the trunk, legs, and
arms and thus minimise the internal and external injury suffered.

5.7.4 To avoid injury due to sudden deceleration, the maximum free fall shall be 2 feet (600 mm) unless some
form of shock absorber or decelerating device is incorporated. For a fall of up to 5 feet (1500 mm),
synthetic fibre rope provides adequate shock absorption. Chain, cable or natural fibre rope shall not be used
unless shock absorbing properties re built into the belt or harness. Friction reel or inertia devices are
acceptable provided that particularly close attention is paid to their proper use and maintenance.

5.7.5 For work in confined spaces, the system provided shall be designed to facilitate rescue of the suspended
worker in the event that he loses consciousness (e.g. due to fumes or oxygen deficiency).

5.7.6 To overcome the restriction of movement caused by the use of the equipment, where safe to do so it is
permitted to use a harness hook attached to an overhead horizontal cable designed for that purpose.

5.7.7 In the event that a safety belt, harness or line has been used to arrest a fall, the equipment shall be fully
tested and re-certified before being used again.
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5.7.8 Relevant British Standards not listed elsewhere in this specification include:

(a) General

Personal protective equipment against falls from a height:

BSEN 341 Descender devices.

BSEN 353 Guided type fall arrestors.

BSEN 354 Lanyards.

BSEN 355 Energy absorbers.

BSEN 360 Retractable type fall arresters.

BSEN 361 Full body harnesses.

BSEN 362 Connectors.

BSEN 363 Fall arrest systems.

BSEN 365 General requirements for instructions for use and for marking.

BSEN 358 Personal protective equipment for work positioning and prevention of falls from a height.
Work positioning systems.

(b) Special uses

BS 3367 Specification for fire brigade & industrial ropes and rescue lines.

(c) Test methods

BSEN 364 Test methods.

5.8 Life Jackets and Buoyancy Aids

5.8.1 Life jackets shall be used by all persons who run a foreseeable risk of drowning when working over water.

5.8.2 A life jacket shall provide sufficient buoyancy to turn face upwards and support an unconscious person:

- with his mouth and nose well clear of the water;

- within five seconds if non-inflatable type, and ten seconds if inflatable type.

5.8.3 Buoyancy aids (which only provide extra buoyancy to assist a conscious person to keep afloat and do not
turn over an unconscious person from a face down position) shall be used only when the use of a life
jacket would result in a higher level of risk to the wearer.

5.8.4 Relevant British Standards not listed elsewhere in this specification include:

Lifejackets and personal buoyancy aids:

BSEN 393 Buoyancy aid 50.

BSEN 394 Additional items.

BSEN 395 Lifejacket 100.

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BSEN 396 Lifejacket 150.

BSEN 399 Lifejacket 275.

5.9 Breathing Protection

5.9.1 Breathing (or respiratory) protection shall be used by all persons who run a foreseeable risk of:

- breathing in harmful substances:

- dusts, mists, particulates, or micro-organisms;
- gases or vapours.
- suffering from oxygen deficiency,

for example where:

- exposures exceed the appropriate occupational exposure limits;
- maintenance is required in high contamination areas;
- emergency escape with portable air supply may be required.

5.9.2 All respiratory protection shall be capable of providing a sufficient quantity of clean air for the wearer to
breathe without difficulty.

5.9.3 As not all models will fit all sizes and shapes of face, a range of equipment for each type of service shall
always be held in stock.

5.9.4 Respiratory protection falls essentially into two categories:

- equipment which has limited use such as (i) face masks with filters and (ii) powered respirators
which both take in contaminated air from the work space and filter or clean it before it is inhaled
(all such devices being termed 'respirators');
- equipment which can be used against any form of non-radioactive contaminant such as (i) air-fed
hoods and (ii) self-contained breathing apparatus which both deliver uncontaminated air to the
wearer from an independent source.

Within these two categories there are further important sub-divisions, there being about 30 different types
in all.

5.9.5 For protection against harmful substances using a respirator, the exact choice of respirator shall be made for
the specific risk in close consultation with the manufacturer, taking into account such factors as:

- toxicity;
- particle size;
- chemical characteristics;
- breakthrough level (when the filter becomes saturated and the hazardous substance passes straight
through it).
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5.9.6 Respirators:

- shall be provided appropriately for low levels of harmful dust;

- SHALL NOT be used where there is any risk of loss of consciousness or asphyxiation.

5.9.7 Breathing air supplied to workers shall:

- contain not more than:

- 5 parts per million (ppm) by volume of carbon monoxide;
- 500 ppm of carbon dioxide.
- have no oil odour;
- be supplied at:
- a temperature of 59 - 68°F (15 - 20°C);
- a maximum relative humidity of 85% with no condensed water;
- a minimum flow rate of 120 litres per minute per person.

5.9.8 Positive pressure self-contained compressed air breathing apparatus shall be provided for all work in
atmospheres which are immediately dangerous to life or health, including:

- underwater work;
- firefighting;
- work in toxic or oxygen-deficient atmospheres.

5.9.9 Escape breathing apparatus shall not be used for normal working or entry into a danger area.

5.9.10 Fresh air hose systems (incorporating a compressor as appropriate) shall be provided for extended duration
activities requiring respiratory protection.

5.9.11 Hose for fresh air equipment shall be strong, flexible and crush- and kink-resistant.

5.9.12 Closed-circuit self-contained breathing apparatus using oxygen shall not be provided at all, for the
following reasons:

a) The presence of oxygen in the atmosphere in a concentration higher than normal will increase the
rate of any combustion.

b) Oxygen may spontaneously react with oils, greases or dirt.

5.9.13 Whenever respiratory protection is being selected for a specific task, appropriate arrangements for essential
communications shall be incorporated.

5.9.14 Those needing to use any form of respiratory protection shall be given specific training with the equipment
which they will use to familiarise them with:

- the correct operating procedure;

- the extra breathing resistance imposed on the lungs;
- the restricted mobility and visibility;
- the weight of the equipment.

5.9.15 In addition, those needing to wear positive pressure breathing apparatus shall be made fully aware that
anything which adversely affects the seal of the mask against the face (e.g. beards and spectacles) will
significantly reduce their level of safety.

5.9.16 For all work in atmospheres which are immediately dangerous to life or health, workers shall be
continuously supervised from outside the danger area, with appropriate communications and rescue
facilities always available.
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5.9.17 All respiratory protection equipment shall be cleaned and disinfected after each use.

5.9.18 Relevant British Standards not listed elsewhere in this specification include:

(a) General

Respiratory protective devices:

BSEN 132 Definitions.

BSEN 133 Classification.

BSEN 134 Nomenclature of components.

BSEN 135 List of equivalent terms.

BS 4275 Recommendations for the selection, use and maintenance of respiratory protective
equipment.

(b) Fresh air

BSEN 138 Respiratory protective devices. Specification for fresh air hose breathing apparatus for
use with full face mask, half mask or mouthpiece assembly - Requirements Testing
marking.

BSEN 269 Respiratory protective devices. Powered fresh air hose breathing apparatus incorporating
a hood.

(c) Compressed air

BSEN 137 Specification for respiratory protective devices:

Self-contained open-circuit compressed air breathing apparatus.

BSEN 139 Respiratory protective devices. Compressed air line breathing apparatus for use with a
full face mask, half mask or a mouthpiece assembly.

BSEN 250 Respiratory equipment. Open-circuit self-contained compressed air diving apparatus.

BSEN 270 Respiratory protective devices. Compressed air line breathing apparatus incorporating a
hood.

BSEN 271 Respiratory protective devices. Compressed air line or powered fresh air hose breathing
apparatus incorporating a hood for use in abrasive blasting operations.

BS 4001 Care and maintenance of underwater breathing apparatus.

(d) Oxygen

BSEN 145 Respiratory protective devices. Self-contained closed-circuit breathing apparatus or

compressed oxygen-nitrogen type.

BSEN 145 Specification for respiratory protective devices. Self-contained closed-circuit compressed
oxygen breathing apparatus.

(e) Self-rescue
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Respiratory protective devices for self-rescue:

BSEN 400 Self-contained closed-circuit breathing apparatus.

Compressed oxygen escape apparatus.

BSEN 401 Self-contained closed-circuit breathing apparatus. Chemical oxygen (KO2) escape
apparatus.

BSEN 402 Self-contained open-circuit compressed air breathing apparatus with full face mask or
mouthpiece assembly.

BSEN 404 Filter self-rescuer.

BSEN 403 Specification for filtering respiratory protective devices with hood for self-rescue from
fire.

BSEN 1146 Breathing Apparatus specification for open-circuit escape breathing apparatus.

(f) Components

Masks and Facepieces

BSEN 136 Requirements Testing Marking - Respiratory protective devices - Full Face Masks.

BSEN 148 Pt. 3 Respiratory protective devices. Threads for facepieces.

BS 7156 Respiratory protective devices. Threads for facepieces.

BS 7309 Specification for mouthpiece assemblies for respiratory protective devices.

BSEN 136 Requirements Testing Marking - Respiratory Protective Devices - Full Face Masks.

BS 7356 Specification for half masks and quarter masks for respiratory protective devices.

Filters

BSEN 141 Respiratory Protective Devices - Gas filters & Combined Filters

BSEN 143 Respiratory Protective Devices - Particle Filters.

BSEN 146 Respiratory protective devices - Particle Filtering devices incorporating helmets or hoods
-Requirements, Testing, Marking.

BSEN 147 Respiratory protective devices. Power assisted particle filtering devices incorporating
full face masks, half masks or quarter masks - Requirements, Testing, Marking.

BSEN 149 Respiratory Protective Devices - filtering half masks to protect against particles -
Requirement, Testing, Marking.

BSEN 372 Specification for SX gas filters and combined filters against specific named compounds
used in respiratory protective equipment.

BSEN 405 Respiratory protective devices. Valved filtering half-masks to protect against gases or
gases and particles - Requirements, Testing, Marking.

BS 4400 Method for sodium chloride particulate test for respirator filters.
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Cylinders and valves

BSEN 144 Pt 1 Respiratory protective devices. Gas cylinder valves.

6.0 EQUIPMENT PURCHASE

6.1 Design and Construction

6.1.1 Only personal protection equipment which has been type approved by a recognised authority shall be
provided.

6.1.2 Only certified materials shall be used for pressure containing systems.

6.1.3 All painting and coating shall be adequate for the intended service.

7.0 INSPECTION AND TESTING

7.1 Inspection

7.1.1 Protective clothing and BA sets will usually be off-the-shelf standard items and, as such, shall be strictly
controlled by the manufacturer's quality control systems.

7.1.2 The Vendor/Contractor always has the responsibility to provide adequate Quality Control and inspection of
equipment and materials. Any inspection by Owner or his Inspector shall not relieve the Vendor/Contractor
of these responsibilities or those under his guarantees.

7.2 Testing

7.2.1 All equipment and materials shall be tested in accordance with the Vendor/Contractor's standard procedures
prior to leaving the Vendor/Contractor's factory.

7.2.2 If so specified on the Purchase Order/Contract, selected testing shall be carried out in the presence of the
Owner's Inspector.

7.2.3 The results of all tests performed shall be recorded on signed test certificates.

7.2.4 The Vendor/Contractor shall provide all consumables, personal and the site, systems and equipment
required for testing.

7.2.5 The Inspector shall ensure than any shortcomings in the Vendor/Contractor's documentation or data are
rectified before any equipment or material is accepted for shipment.

8.0 DOCUMENTATION

8.1 Introduction

8.1.1 This section covers the documentation required for the design, selection, fabrication, inspection and testing
for all the equipment, components and services to be provided against this specification.

8.1.2 The detailed list of documents that are required is included with the Purchase Order/Contract, however as a
 GENERAL ENGINEERING SPECIFICATION GES H.11
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minimum the following listed documents will be provided by the Vendor/Contractor as and when required
by the Vendor Documentation Requirements (VDR) list:

. Instructions for Use;

. Test Certificates;
. Maintenance Procedures where relevant.

8.1.3 The documents as listed may be considered as a minimum requirement; all details to confirm compliance
with the relevant specifications, and to allow a full and continued appraisal to be made of the
Vendor/Contractor's proposals and interpretations of the ordered equipment, should be submitted in
accordance with the schedule specified in the Purchase Order/Contract.

8.1.4 Any production or procurement undertaken by the Vendor/Contractor which is prior to the relevant
documentation being submitted and reviewed by the Owner is at the Vendor/Contractors risk.

8.1.5 On all documentation the Purchase Order/Contract number, equipment title, tag number and project name
shall be quoted.

8.1.6 All documentation shall be checked and signed by the checker before submission.

8.2 Schedules and Reports

8.2.1 The Vendor/Contractor shall submit with his tender a preliminary quality control plan and proposals for
Factory acceptance and site acceptance tests.

8.2.2 The Vendor/Contractor shall include with his tender documentation a statement of proposed Sub-
Vendors/Sub-Contractors, a document submission schedule for all documents based on a review cycle of
three weeks and outline programme for procurement and production activities.

8.2.3 The Vendor/Contractor shall incorporate any revisions agreed with the Owner during the enquiry review
stage.

8.2.4 Monthly reports shall be submitted by the Vendor/Contractor detailing design, procurement, production
and documentation activities, the format of which shall be agreed with the Owner.

8.3 Data and Calculations

8.3.1 The Vendor/Contractor shall supply with his tender completed Data Sheets containing all the relevant
information necessary for appraisal of the design by the Owner.

8.3.2 Project specific instructions will be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted, and the methods of submission.

8.3.3 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.

8.3.4 All calculations shall be carried out in clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be
clearly referenced.

8.4 Drawings

8.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
and/or the Inspection Authority for review and approval.

8.4.2 The components and process to produce the ordered equipment shall be shown in sufficient detail to be
fully appraised.
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8.5 Final Records, Documents and Manuals

8.5.1 Two copies of the Data Dossier shall be supplied, and shall be a record of the manufacturing process.
Where stated in the Purchase Order/Contract, besides the documents itemised in Section 8.1.2, it shall
contain the following:

- the quality control plan;

- material certificates;
- positive material identification certificates;
- NDT procedures and records;
- non-conformity records;
- approvals by the Independent Inspection Authority;
- certificate of conformity;
- Owner's release certificate.

8.5.2 Six sets of the Installation, Operations and Maintenance Manual (IOM) shall be specifically compiled for
the equipment supplied. A compendium of manufacturer's data for a range of like products is not
acceptable. The IOM shall contain the following:

- a description of the equipment;

- the master document list and certified copies of key drawings;
- packing, shipping and site preservation instructions;
- spare parts ordering information.

The IOMs shall be presented in A4 format, and be securely bound in heavy duty 4 ring binders.

8.5.3 The Vendor/Contractor shall produce as built documents revised to indicate field changes.

8.5.4 The Vendor/Contractor shall supply one set of mylar original drawings.

8.5.5 Electronic Data Format (EDF)

All documentation (drawings, calculations and Data Sheets etc.) shall be produced by the
Vendor/Contractor in electronic format.

The format shall be compatible with that used by the Owner and shall be agreed at the commencement of
the contract.

In addition to the 'hard copies' required under the contract, copies of the electronic records shall be issued
to the Owner for all approved documentation, this forming part of the Vendor/Contractor's contractual
obligations.

9.0 PRIOR TO SHIPMENT

9.1 Painting and Coatings

Where relevant all bare surfaces which are exposed during transit or storage shall be given a coat of
temporary rust inhibiting material.

9.2 Spares

The Vendor/Contractor shall submit with his proposal a priced list of recommended spares for start-up and
two years operation for review by the Owner. This list shall include, but not be limited to:

- special tools, if required;

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- limited shelf-life equipment replacements.

9.3 Packing and Storage

This section describes the minimum requirements for the preservation and protection of equipment during
the sea and land transportation and storage prior to installation.

The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24
months shall be assumed. Packing to be suitable for sea freight.

(a) After mechanical completion at the works, the equipment shall be left in a clean dry condition.

(b) The Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent
damage during shipment.

The Vendor/Contractor shall submit his procedures for packing and preservation for review by the Owner.

9.4 Shipping

Detailed shipping arrangements are covered by the Purchase Order/Contract.

The equipment shall not leave the Vendor/Contractor's works for shipment until the release has been
approved by the Owner's Inspector.

9.5 Warranty

The Vendor/Contractor shall warrant all material and services supplied against any defect for a period of
twelve (12) months after commissioning, or twenty-four (24) months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.12

HP CYLINDERS STORAGE AND HANDLING

Rev Date Description By App

0 June 94 Draft Issue for Comment DM RDW
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INDEX

SECTION TITLE PAGE

1.0 SCOPE OF SPECIFICATION

1.1 Introduction.
1.2 Plant Description
1.3 Codes and Standards
1.4 Other NOC Specifications
1.5 Definitions

2.0 PLANT RATING

2.1 Capacity
2.2 Environment

3.0 HANDLING

3.1 Identification
3.2 Carriage
3.3 Additional Recommendations

4.0 STORAGE

4.1 Location
4.2 Security
4.3 Topic and Corrosive Gases

5.0 DESIGN

5.1 Materials
5.2 Piping

6.0 INSTRUMENTATION

6.1 Control Systems

6.2 Hardware

7.0 SAFETY SYSTEMS

7.1 Safety Equipment

7.2 Safety Procedures
7.3 Leak Detection
7.4 Fire

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SECTION TITLE PAGE

8.0 INSPECTION AND TESTING

8.1 Inspection
8.2 Performance Testing

9.0 DOCUMENTATION

9.1 Introduction
9.2 Schedules/Reports
9.3 Data and Calculations
9.4 Drawings
9.5 Manuals

10.0 PRIOR TO SHIPMENT

10.1 Paintings and Coatings

10.2 Spares
10.3 Packing and Storage Precautions

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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

The scope of this Specification covers the use of high pressure cylinders for the
storage of of industrial gases. Aso included are the requirements to ensure safe
operation of the cylinders.

1.2 Plant Description

1.2.1 Cylinder Valves and Security Caps

The Vendor shall ensure that all cylinders containing gas at high pressure are fitted
with a cylinder valve which must not be removed or tampered with at any time except
to tighten the gland nut when necessary.

Some cylinders have a security cap over the cylinder valve indicating that they have
been filled and checked. This cap is removed by rotating the hexagon nut in either
direction using the regulator spanner, this will cause the cap to split for easy removal.
Each valve outlet is specially threaded to receive standard pressure regulators. These
should be screwed in by hand and then tightened using the regulator spanner. To open
the cylinder valve, rotate the spindle anti-clockwise using the special spindle key.

Some cylinders are fitted with handwheels obviating the need to use a spindle key.
Such cylinders and some others fitted with valves are normally fitted with valve
guards or valve protection caps. Valve guards should not be removed. Valve
protection caps should always be replaced after use. Always return your cylinder with
the valve in the closed position.

1.2.2 Valve Outlet Threads

To prevent the interchange of fittings between cylinders containing combustible gases

and non-combustible gases, the cylinder valve outlets are threaded to opposite hands.
Non-combustible gases, like oxygen, nitrogen, argon and air, all should have
conventional right-hand threads. Combustible gases like acetylene, hydrogen,
propane and mixtures containing fuel gas all have left-hand threads, except FLT
propane cylinders.

The only exceptions are special cylinders of dissolved acetylene, specified for
purposes other than welding and cutting and some propane cylinders used on fork lift
trucks, these cylinders have right-hand thread valve outlets.

These precautions mean that oxygen and fuel gas pressure regulators are not
interchangeable. Spindle keys, however, are interchangeable.

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The cylinder valves on all gas cylinders, whether they contain combustible or
non-combustible gas, shall be opened by turning the spindle anti-clockwise and closed
by turning the spindle clockwise.

1.2.3 Cylinder Identification

All cylinders shall be labelled in accordance with the Classification, Packaging and
Labelling of Dangerous Substances Regulations.

Cylinder labels identify the gas contents of the cylinder and provide basic safety
information.

1.3 Codes and Standards

BS 341 Part 1: 1991 - Valve Fitting for Compressed Cylinders

BS 349: 1973 - Identification of Contents of Industrial Gas

Containers

BS 5430 Parts 1, 2, 3: 1990 - Periodic Inspection, Testing and

Maintenance of Transportable Gas
Containers

HOAL - Home Office Specifications for Seamless

Aluminium Alloy Containers for the
Conveyance of Compressed and Liquefied
Gases

HOS - Home Office Specifications for Stainless

Alloy Steel Cylinders for the Conveyance of
Compressed Gases

SI 2169 - Pressure System and Transportable Gas

Containers Regulation 1989

British Compressed Gases Association Publications

CP3 - The Safe Disposal of Gas Containers

CP8 - The Safe Storage of Gaseous Hydrogen in

Seamless Cylinders and Similar Containers

CP10 - Industrial Compressed Gas Container Valves

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and Fittings (Parts 1, 2 & 3)

CP12 - The Safe Use of Non-refillable Gas

Containers (Cylinders)

CP13 - Classification, Packaging and Labelling of

Dangerous Substances Regulations SI 1984
1244

CP15 - The Safe Re-rating of Existing BS 5045

Part 1: 1982 Containers to Amendment and
5145 1986

1.4 Other NOC Specifications

GES U.16 - LPG Storage and Handling

1.5 Definitions

1.5.1 Technical

The technical terms used in this specification are defined as follows.

Flashback Arrestor

The arrestor quenches a flame front travelling in a direction opposite to the normal
flow. Flashback arrestors often incorporate other safety features which may include
non-return valves, cut-off valve and safety valves.

Snifting

Venting momentarily to blow any debris from the cylinder valve outlet.

1.5.2 Contractual

The commercial terms used in this specification are defined as follows.

Owner

The Oil or Gas company, an associate or subsidiary, who are the end user of the
equipment.

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Purchaser

The company buying the equipment for or on behalf of the Owner.

Vendor

The company supplying the equipment.

Contractor

The main contractor for a defined piece of work.

Inspection Authority

The organisation that verifies that the equipment has been designed, constructed,
inspected and tested in accordance with the requirements of this specification.

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2.0 PLANT RATING

2.1 Capacity

The capacity of bulk storage cylinders or vessels are designated according to the
amount of liquid gas they contain at the designated pressure. Vendors shall require to
specify this information relative to the particular gaseous material supplied to the
Contractor.

2.2 Environment

Wherever cylinder gases are used, there should be maintained constant and thorough
ventilation. This is particularly important when the gases are used in confined spaces.

The environment can be contaminated or adversely affected by one or more of the

following hazards:

- oxygen enrichment;
- oxygen deficiency;
- accumulation of fuel gases.

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3.0 HANDLING

3.1 Identification

The supply of any cylinder should not be accepted if its contents cannot be positively
identified. Great care must be taken to label cylinders clearly. When taking delivery
or collecting cylinders, check the label against requirements.

3.2 Carriage

3.2.1 On the Road

Gas cylinders can be carried safely on road vehicles provided sensible precautions are
taken. The Road Traffic (Carriage of Dangerous Substances in Packages, etc)
Regulations 1986 apply to the carriage on road vehicles of flammable and toxic gases.
In practice, the same principles should be applied whatever gases are being carried.

The main points are:

- make sure that all concerned are aware which gases are being carried and which
are flammable, toxic or corrosive;
- make sure the driver carries the information card and the appropriate gas data and
safety sheets;
- make sure the cylinders are properly loaded and secured so that they cannot move
about and do not project beyond the sides or end of the vehicle;
- make sure acetylene and propane cylinders are carried and secured upright;
- make sure the cylinders are labelled properly;
- make sure there are no leaks of gas;
- where possible use an open vehicle. If a closed van or car has to be used make
sure it is properly ventilated at all times. At least have a window open and ensure
cylinders are leak checked thoroughly just before loading them;
- do not carry toxic gas cylinders (painted yellow or having yellow markings) in a
closed vehicle, unless in a ventilated compartment separate from the driver;
- do not smoke or ignite flammable materials when transporting or handling
cylinders;
- remove all equipment from cylinders;
- check caps and plugs are fitted and refit any which are not in place;
- unload all cylinders as soon as possible;
- do not use cylinders in a closed vehicle;
- if you suspect a leak whilst in transit, stop, park in a safe place, check, and if
necessary, phone for assistance. Phone the fire brigade in an emergency and
advise them of the number of cylinders and their contents;

- if you are in a road accident whilst carrying cylinders and the emergency services

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are called, tell them you are carrying gas cylinders and tell them what gas is in
them. Show the appropriate gas data and safety sheets;
- if you are carrying cylinders which when full would contain 500 kg or more of
propane, acetylene, hydrogen or a toxic gas such as ammonia, you are required to
have orange plates on the front and rear of your vehicle as required by the 1986
regulations;
- if you carry flammable gas cylinders on your vehicle make sure you have
fire-fighting equipment in the vehicle and that all concerned are familiar with its
use.

3.2.2 In the Works

Movement of cylinders within the works boundaries should be carried out with the
same care as when moving them on the general highway. Cylinders must be properly
secured when being moved and, if transported in a van, precautions must be taken to
avoid build-up of gas which might affect the driver. Cylinders must not be
transported with equipment fitted.

3.2.3 Lifting Cylinders

There is a wide range of methods of lifting cylinders, the golden rule is that the
cylinder must be secure during the lift. Never lift a cylinder with magnets or chains or
slings. Be aware of the hazards of manually handling large cylinders, particularly of
cylinders sliding away when lifting from the horizontal to the vertical or vice versa.
Do not attempt to catch a toppling cylinder - get out of the way.

3.3 Additional Recommendations

Rolling cylinders along the ground damages the identification of the cylinder and may
also cause the valve to be damaged or opened. `Milk churning' cylinders on their
bases is permissible and operators frequently become skilled in this technique, but it is
not recommended for transporting over long distances or uneven ground. For
preference, use a cylinder trolley.

When using a cylinder trolley to move cylinders, make sure cylinders are properly
located and secured and the cylinder valves are shut. Never transport cylinders with
the pressure regulator and hose attached, unless on a purpose designed trolley or
carrier. Sack barrows and other similar trucks are not ideal for carrying cylinders, but
if there is no alternative, pay strict attention to securing the cylinders and always
remove the pressure regulators.

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4.0 STORAGE

4.1 Location

Small holdings of cylinders may be stored in a variety of locations, provided that the
principles given in the following paragraphs are followed. Larger quantities of
cylinders should be kept in a purpose designed store or storage area, following the
same principles.

Full or empty compressed gas cylinders should be stored in a well ventilated area -
preferably in the open, but with some weather protection. Cylinders should be stored
securely on a well drained surface to prevent corrosion. Store cylinders in a location
free from fire risk and away from sources of heat and ignition.

4.2 Security

It is best to store all cylinders upright, taking steps to see that they are secured to
prevent them falling. Free standing cylinders are a hazard to users and passers-by.
Acetylene and propane must never be stacked horizontally in storage or in use.
Vertical cylinders should always be secured or under your direct control, never turn
your back on a free standing cylinder. When standing or churning cylinders, be aware
of the hazards of uneven sloping, slipper and vibrating surfaces as well as loose
debris. Whenever possible use a cylinder trolley for transporting large cylinders.

4.3 Toxic and Corrosive Gases

Toxic and corrosive gases should be stored separately from all other gases.

It is essential that when handling or storing cylinders containing toxic or corrosive

gases that the plug or cap nut is always replaced in the valve outlet when the cylinder
is not in use or connected to an operational system.

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5.0 DESIGN

Gas cylinders shall be designed and constructed in accordance with Home Office
Specifications and/or British Standards. These standards define the material of which
the cylinder is made, the method of construction, its test pressure, the maximum
permissible filled pressure and the method of regular testing. The latest British
Standards are summarised in Section 1.2.

5.1 Materials

HP cylinders are used to store the following gases and each shall be identified by the
colour of the cylinder as stated below:

Oxygen - Black
Nitrogen - Grey (with black shoulder)
Argon - Blue
Propane - Bright Red (bearing the word propane)
Acetylene - Maroon
Hydrogen - Bright Red
Carbon Dioxide - Black (with two vertical white lines)
Helium - Brown (with beige shoulder)

5.2 Piping

Depending on the customers preference, pipework may be exposed and run at high or
low level, or run under suspended wooden floors or through the roof space.

Pipework may be run in specially prepared ducts in solid floor or buried in the floor
screed, but if it is to be cemented in, the pipe and fittings must be protected against
corrosion.

Pipework may also be run externally, clipped to the wall at high or low level and
brought into the building close to the point of use. This may be particularly
convenient where two or more appliances are installed at points remote from one
another, since it minimises disturbance and damage to internal finishes. Where
pipework passes through walls, particularly cavity wall, it must be enclosed in a
sleeve without joints. Pipework must pass straight through and may not run within
the cavity, parallel to the walls.

The service pipe and sleeve shall be constructed and installed to prevent gas passing

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along the space between the pipe and the sleeve, and between the sleeve and the wall
or floor so as to allow normal movement of the pipe, e.g. a flexible seal between the
pipe and the sleeve at each end. Whatever route is chosen, pipes must be properly
clipped and supported clear of the wall.

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6.0 INSTRUMENTATION

6.1 Control Systems

Before fitting a pressure regulator on to a full cylinder ensure that the pressure
adjusting screw is screwed out so that there can be no flow through the regulator when
the cylinder valve is opened.

Left-hand threaded pressure regulators should not be interchanged between gases, also
left-hand to right adaptors should not be used.

To prevent flames travelling back into cylinders, flashback arrestors should be fitted
downstream of pressure regulators in oxygen, acetylene, propane and hydrogen
systems. Where cylinders are connected to a manifold or header, the system must be
fitted with one or more pressure regulators.

6.2 Hardware

The pressure regulators used shall be designed for use with high pressure gas
cylinders, also it should be ensured that the threads are the same as on the valve
outlet.

For the prevention of backfeeding, a non-return or check valve can be fitted. A more
reliable alternative is the fitting of an automatic shut-off/isolation valve. This is
activated by a low pressure signal when the supply gas cylinder pressure reaches a
level that requires the cylinder to be replaced.

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7.0 SAFETY SYSTEMS

7.1 Safety Equipment

When a pressure regulator is fitted with pressure gauges, these should never be
removed, exchanged or tampered with in any way. If a gauge leaks, the entire
pressure regulator should be taken to the supplier.

The best quality hose, such as that supplied by the British Oxygen Company must be
used at all times.

Flashback arrestors should be used. This device is designed to quench the flashback
and when it incorporates a cut-off valve will automatically shut-off the gas flow.

7.2 Safety Procedures

(a) Excessive heat on cylinders results in an increase in internal pressure resulting in

the weakening of the cylinder wall and making it bulge.

(b) Electrical welding tools must not be allowed to touch or get near to cylinders. An
accidental arc between the tool and the cylinder could overheat the cylinder wall.

(c) Cylinder valves should be kept clean, free from grit, dirt, oil or dirty water, if not
leakage may occur.

(d) Snifting, the cracking open and immediately closing of a cylinder valve to remove
dirt or residual moisture, should never be carried out with a hydrogen cylinder as
it may ignite spontaneously.

(e) Cylinders should be kept free from oil and grease at all times, likewise jointing
compounds should not be applied.

(f) With valve operation, use care, not force. Valves should be opened slowly using
the correct spindle key, not subject to excessive torque. An opened valve should
never be left against the backstop, but should be turned back at least half a turn to
avoid seizure in an open position.

(g) Regular checks for faults and leaks should be carried out, with special attention to
pressure regulators. Cylinders should be checked for leaks both when they are in
store and when they are assembled with equipment for use. Special attention
should be paid to all joints and blowpipe valves. Those assemblies which show
any sign of deterioration should be discarded.

(h) Frozen regulators or valves, caused by excessive flow rates shall be thawed with

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hot water, never by flame.

7.3 Leak Detection

Cylinders should be inspected regularly for leakage.

Never attempt to find a leak by means of a naked flame.

Leakage can be detected in any of the following ways:

(a) by means of smell;

(b) by sound of escaping gas;

(c) by condensation or frosting round the leak;

(d) leaks may be confirmed by brushing soapy water over the suspected leak
source.

If a gas leak is suspected:

(a) do shut all valves on tank or cylinders and energy control valves outside
the building;

(b) do open all doors and windows;

(c) do ventilate at floor level and low level areas and cellars (LPG is heavier
than air);

(d) do not operate electrical switches - on or off;

(e) do not smoke or use naked flames and make sure they are no other sources
of ignition around.

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7.4 Fire

The following actions should be taken in the event of a fire being discovered:

a) evacuate the area (minimum 100 metres);

b) call the fire brigade;
c) advise persons between 100 and 300 metres from the cylinder to take
cover;
d) if you attempt to fight the fire, do so from a protected position using
copious quantities of water;
e) when the fire brigade arrives inform them of the location and number of
gas cylinders directly involved in the fire, and the names of the gases they
contain;
f) cylinders which are not directly involved in the fire and which have not
become heated should be moved as quickly as possible to a safe place,
provided this can be done without undue risk. Make sure these cylinder
valves are closed.

Any cylinders which have been exposed to excessive heat, should be clearly marked.

8.0 INSPECTION AND TESTING

8.1 Inspection

Inspection requirements shall be as specified in the purchase order, the Inspector will
not release materials which do not comply with the purchase order and cannot be
identified with applying specifications, or in the opinion of the Inspector, the
workmanship is unacceptable.

If inspection is conducted, the required number of copies of test data or other

acceptable material data, code forms, charts and other required information shall be
given to the Inspector at the time of or before final inspection.

If inspection is waived, the required data, including reports of chemical and physical
properties and certificates needed to verify compliance with local rules and regulating,
shall be forwarded to the Client. If submission of data is not requested, all data shall
be retained by the manufacturer or supplier for at least 18 months.

Inspection by the Inspector does not relieve the manufacturer of its obligation to
provide its own quality control and inspection of materials and equipment to ensure
that the order requirements are met. Neither does such inspection relieve the
manufacturer/Vendor of guarantees as to material, apparatus, workmanship or
performance or both.

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8.2 Performance Testing

The Vendor shall conduct a functional test of all supply tanks and cylinders supplied.
These tests shall be witnessed by the Inspector.

If the Contractor owns his cylinders, he must be aware of and discharge his statutory
obligations with regard to maintenance and testing as qutoted in BS 5430. If the
cylinders are rented from a Vendor, then the Vendor is responsible for these functions.

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9.0 DOCUMENTATION

9.1 Introduction

Material data shall be furnished with all HP cylinder storage equipment. The material
data shall be furnished with the required final drawings and parts information.

9.2 Schedules/Reports

A production schedule shall be prepared by the Vendor, for the approval of the
Purchaser. After an order is placed, this shall be updated and re-submitted at an
interval to be agreed between the Purchaser and the Vendor.

Similarly, a progress report shall be issued by the Vendor at the same intervals as the
production schedule.

A co-ordination meeting shall be held within six weeks of the purchase order being
placed.

9.3 Data and Calculations

Data for proposals shall be submitted by the Vendor. Contractual data shall be
provided by the Purchaser.

9.4 Drawings

Review and approval of drawings shall be according to the commercial section of the
proposal/contract. Proposal and contractual drawings shall be provided by the
Vendor.

Final technical documents shall be furnished complete with the following references:

(a) manufacturer's name;

(b) Client's name;

(c) identification code established by Client;

(d) title of documents;

(e) details of Client purchase order.

DE302/NOC9077/HPCYLIN.U17
 GENERAL ENGINEERING SPECIFICATION GES H.12
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Rev 0 1994

General arrangement drawings shall show the relative location and main dimensions
of all components.

Documents and drawings to be approved, and those required for design and sent
beforehand shall form part of final documentation.

9.5 Manuals

A data book shall be provided, also an installation, operating and maintenance

manual.

Data Book

On completion of test and acceptance, the data book shall contain the following:

(a) all drawings including "as-built" drawings;

(b) design and installation instructions;

(c) maintenance instructions.

DE302/NOC9077/HPCYLIN.U17
 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 21
Rev 0 1994

10.0 PREPARATION FOR SHIPMENT

10.1 Paintings and Coatings

Painting shall comply with NOC Specification GES X.1.

10.2 Spares

With his proposal, the Vendor shall provide a list of spares suitable for commissioning
and two years' operation, for review by the Purchaser.

After review/approval of the list by the Purchaser, these spares shall be ordered and
delivered with the main equipment.

10.3 Packing and Storage Precautions

Preservation/protection requirements for sea transport shall be advised by the Vendor.

The Vendor shall recommend procedures for storage up to two years.

DE302/NOC9077/HPCYLIN.U17
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.12

HP CYLINDERS STORAGE AND HANDLING

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 2 of 13
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 4

2.1 Technical 4
2.2 Contractual 5

3.0 DESIGN 5

3.1 Codes and Standards 5

4.0 HP CYLINDERS 6

4.1 Cylinder Valves and Security Caps 6

4.2 Cylinder Valve Outlet Threads 7
4.3 Cylinder Labelling 7

5.0 CYLINDER HANDLING 7

5.1 Identification 7
5.2 Carriage 7
5.3 Additional Recommendations 9

6.0 STORAGE 9

6.1 Location 9
6.2 Security 9
6.3 Topic and Corrosive Gases 9

7.0 CONSTRUCTION 10

7.1 Cylinders 10
7.2 Piping 10

8.0 INSTRUMENTATION 10

8.1 Control Systems 10

8.2 Hardware 10

9.0 SAFETY SYSTEMS 11

9.1 Safety Equipment 11

9.2 Safety Procedures 11
9.3 Leak Detection 11
9.4 Fire 12

INDEX
 GENERAL ENGINEERING SPECIFICATION GES H.12
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Rev 0 1999
SEC TITLE PAGE

10.0 PRIOR TO SHIPMENT 13

10.1 Painting and Coatings 13

10.2 Spares 13
10.3 Packing and Storage 13
10.4 Shipping 13
10.5 Warranty 13
 GENERAL ENGINEERING SPECIFICATION GES H.12
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Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 The scope of this specification provides users with the minimum requirements for guidance on safety and
operational requirements for HP cylinder storage and handling.

1.1.2 Personnel responsible for, or working in areas where HP cylinders are stored and handled shall be trained
to implement the applicable Codes, Standards and emergency actions required for the safe control of the
cylinders, as applicable to the specific installation and the fluid contents handled.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved by the Owner.

GES U.16 LPG Storage and Handling

GES X.01 Surface Preparation and Painting Application

GES X.02 Colour Coding of Equipment and Piping

GES X.03 External Protective Coatings

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Cylinder

A portable, compressed gas container, fabricated to authorised standards or to the "Rules for the
Construction of Unfired Pressure Vessels", Section VIII, ASME Boiler and Pressure Vessel Code.

Handling

Moving, connecting or disconnecting a compressed or Liquefied gas cylinder.

LPG

Liquefied Gas Petroleum

Storage

An inventory of compressed or liquefied gases in containers that are not in the process of being examined,
serviced, refilled, loaded or unloaded.

Valve Outlet Caps and Plugs

Removable caps and plugs that form a gas-tight seal on valve outlets for specific gases and, in some cases,
provide valve nozzle and thread protection.

Valve Protection Device

A device attached to the neck ring or body of the cylinder for the purpose of protecting the cylinder valve
 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 5 of 13
Rev 0 1999
from being struck or damaged from impact from a fall or an object striking the cylinder.

Valve Protection Cap

A rigid, removable cover provided for compressed gas container valve protection.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

3.1.1 The designs and requirements shall comply with this specification and the following Codes and Standards:

BS 341 Part 1 Transportable Gas Container Valves - Specification for Industrial Valves for
Working Pressures up to and including 300 BAR

BS EN 1089 Pt. 3Transportable Gas Cylinders - Cylinder Identification - Colour Coding

BS EN 1440 Transportable, Refillable Welded Steel Gas Cylinders for LPG - Procedure for
checking before, during and after filling

BS EN 1442 Transportable, Refillable Welded Steel Cylinders for Liquefied Petroleum Gas
(LPG) - Design and Construction
 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 6 of 13
Rev 0 1999
BS EN 1762 Rubber Hoses and Hose Assemblies for Liquefied Petroleum Gas, LPG (Liquid
or Gaseous Phase) and Natural Gas up to 25 bar (2,5 MPA) - Specification

BS 5306 Fire Extinguishing Installations and Equipment on Premises - Guide for the Selection of
Installed Systems and Other Fire Equipment

BS 5430 Parts 1, 2, 3 Periodic Inspection, Testing and Maintenance of Transportable Gas Containers

ASME VIII Boiler and Pressure Vessel Code - Rules for Construction of Pressure Vessels

British Compressed Gases Association Publications

CP3: The Safe Disposal of Gas Containers

CP8: The Safe Storage of Gaseous Hydrogen in Seamless Cylinders and Similar
Containers

CP12: The Safe Use of Non-refillable Gas Containers (Cylinders)

CP15: The Safe Re-rating of Existing BS 5045 Part 1: 1982 Containers to Amendment
and 5145

National Fire Protection Association

NFPA 30 Flammable and Combustible Liquids Code

NFPA 55 Storage, Use and Handling of Compressed and Liquefied Gases in Portable
Cylinders

NFPA 58 LP-Gas Code

NFPA 59 Storage and Handling of Liquefied Petroleum Gases at Utility Gas Plants

Health & Safety A Guide to the Road Traffic (Carriage of Dangerous Substances in Packages
etc) Executive Regulations

4.0 HP CYLINDERS

4.1 Cylinder Valves and Security Caps

The user shall ensure that all cylinders containing gas at high pressure are fitted with a cylinder valve
which shall not be removed or tampered with at any time, except to tighten the gland nut when necessary.

The cylinder valves on all gas cylinders, whether they contain combustible or non-combustible gas, shall be
opened by turning the spindle anti-clockwise and closed by turning the spindle clockwise.

Some cylinders may have a security cap over the cylinder valve indicating that they have been filled and
checked. This cap is removed by rotating the hexagon nut in either direction using the regulator spanner,
this will cause the cap to split for easy removal. Each valve outlet is specially threaded to receive standard
pressure regulators. These shall be screwed in by hand and then tightened using the regulator spanner. To
open the cylinder valve, rotate the spindle anti-clockwise using the special spindle key.

Some cylinders are fitted with handwheels obviating the need to use a spindle key. Such cylinders and
some others fitted with valves are normally fitted with valve guards or valve protection caps. Valve guards
shall not be removed. Valve protection caps shall always be replaced after use. Always return cylinders
 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 7 of 13
Rev 0 1999
with the valve in the closed position, when emptied or after use.

4.2 Cylinder Valve Outlet Threads

To prevent the interchange of fittings between cylinders containing combustible gases and non-combustible
gases, the cylinder valve outlets are threaded to opposite hands. Non-combustible gases, oxygen, nitrogen,
argon and air, shall generally have conventional right-hand threads. Combustible gases including
acetylene, hydrogen, propane and mixtures containing fuel gas shall have left-hand threads, except that
right hand threaded valves are permitted in certain special cases as follows:

(a) acetylene for specialised purposes other than welding and cutting;

(b) propane cylinders used to power fork lift trucks.

The above precautions mean that oxygen and fuel gas pressure regulators are not interchangeable. Spindle
keys, however, are interchangeable.

4.3 Cylinder Labelling

All cylinders shall be labelled in accordance with the Classification, Packaging and Labelling of Dangerous
Substances Regulations.

The cylinder label shall identify the gas contents of the cylinder and provide basic safety information.

5.0 CYLINDER HANDLING

5.1 Identification

The supply of any cylinder shall not be accepted if its contents cannot be positively identified. Great care
must be taken to label cylinders clearly. When taking delivery or collecting cylinders, check the label
against the requirements of BS 349 or agreed procedures.

5.2 Carriage

5.2.1 On the Road

Gas cylinders may be carried safely on road vehicles provided the required precautions are taken. The
Health & Safety Executive Road Traffic (Carriage of Dangerous Substances in Packages, etc) Regulations
or the locally approved equal national standard shall apply to the movement by road of flammable and toxic
gases. In practice, the same principles shall be applied whatever gases are being carried and shall ensure
that:
 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 8 of 13
Rev 0 1999
- the fluids within the cylinders can easily be identified as being flammable, toxic or corrosive;

- the driver carries the information card and the appropriate gas data and safety sheets;

- the cylinders are properly loaded and secured so that they cannot move about and do not project
beyond the sides or end of the vehicle;

- all individual cylinders are carried and secured upright;

- the cylinders are labelled properly;

- there are no gas leaks;

- where possible use an open vehicle, (if a closed van or car has to be used make sure it is properly
ventilated at all times. At least have a window open and ensure cylinders are leak-checked
thoroughly just before loading them);

- toxic gas cylinders (painted yellow or having yellow markings) are not transported in a closed
vehicle, unless in a ventilated compartment separate from the driver;

- no flammable materials are carried when transporting or handling cylinders;

- all attached equipment is removed from cylinders;

- caps and plugs are fitted and in place;

- all cylinders are unloaded as soon as possible;

- cylinders are not placed in a closed vehicle;

- if a leak is suspected whilst in transit, stop, park in a safe place, check, and if necessary, phone for
assistance, (phone the fire brigade in an emergency and advise them of the number of cylinders
and their contents);

- should a road accident occur whilst carrying cylinders and the emergency services are called,
inform them of the gas cylinder type and contents, (show the appropriate gas data and safety
sheets);

- any local or accepted regulations are implemented and adhered to, particularly for hazardous
substances including liquid/gaseous petroleum products, chlorine, acetylene, hydrogen, ammonia
or toxic chemicals;

- fire-fighting equipment is available in the vehicle and that personnel are familiar with its use.

5.2.2 In the Works

Movement of cylinders within the works boundaries shall be carried out with the same care as when
moving them on the general highway. Cylinders shall be properly secured when being moved and, if
transported
in a van, precautions must be taken to avoid build-up of gas which might affect the driver. Cylinders shall
not be transported, in the works, with equipment fitted.
 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 9 of 13
Rev 0 1999
5.2.3 Lifting Cylinders

There are a wide range of methods for lifting cylinders. The critical requirement is that the cylinder shall be
secured during the lift. Never lift a cylinder with magnets or chains or slings. Be aware of the hazards of
manually handling large cylinders, particularly of cylinders sliding away when lifting from the horizontal to
the vertical or vice versa. Do not attempt to catch a toppling cylinder - get out of the way.

5.3 Additional Recommendations

5.3.1 Rolling cylinders along the ground damages the identification of the cylinder and may also cause the valve
to be damaged or opened. 'Milk churning' cylinders on their bases is permissable but it is not recommended
for transporting over long distances or over uneven ground. A cylinder trolley shall be used in preference
for moving cylinders.

When using a cylinder trolley make sure cylinders are properly located and secured and the cylinder valves
are shut. Never transport cylinders with the pressure regulator and hose attached, unless on a purpose
designed trolley or carrier. Strict attention to securing cylinders without any attachments, ensuring that the
pressure regulator is removed, is essential for safe transportation.

6.0 STORAGE

6.1 Location

Small holdings of cylinders may be stored in a variety of locations, provided that the principles given in the
following paragraphs are followed. Larger quantities of cylinders shall be kept in a purpose designed store
or storage area, following the same principles.

Full or empty compressed gas cylinders shall be stored in a well ventilated area - preferably in the open,
and with some weather protection. Cylinders shall be stored securely on a well drained surface to prevent
corrosion. Store cylinders in a location free from fire risk and away from sources of heat and ignition.

6.2 Security

6.2.1 All cylinders shall be stored upright, taking steps to see that they are secured to prevent them falling. Free
standing cylinders are a hazard to users and passers-by. Acetylene and propane cylinders shall never be
stacked horizontally in storage or in use. Vertical cylinders shall always be secured. When standing
cylinders, be aware of the hazards of uneven sloping, slippery and vibrating surfaces as well as loose
debris. Whenever possible use a cylinder trolley for transporting large cylinders.

6.3 Toxic and Corrosive Gases

6.3.1 Toxic and corrosive gases should be stored separately away from all other gases.

It is essential that when handling or storing cylinders containing toxic or corrosive gases that the plug or
cap nut is always replaced in the valve outlet when the cylinder is not in use or connected to an operational
system.
 GENERAL ENGINEERING SPECIFICATION GES H.12
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Rev 0 1999

7.0 CONSTRUCTION

7.1 Cylinders

Gas cylinders shall be designed and constructed in accordance with the Codes and Standards listed in
Section 1.2, either to British Standards or American Standards. These standards defined the material of
which the cylinder is made, the method of construction, its test pressure, the maximum permissable filled
pressure and the method of regular testing.

7.2 Piping

Depending on the user's preference, pipework may be exposed and run at high or low level, or run under
suspended wooden floors or through the roof space.

Pipework may be run in specially prepared ducts in solid floor or buried in the floor screed, and shall not be
cemented in. All pipe and fittings shall be protected against internal and external corrosion as applicable.

Pipework may also be run externally, clipped to the wall at high or low level and brought into the building
close to the point of use. This may be particularly convenient where two or more appliances are installed at
points remote from one another, since it minimises disturbance and damage to internal finishes. Where
pipework passes through walls, particularly cavity wall, it must be enclosed in a sleeve without joints.
Pipework must pass straight through and may not run within the cavity, parallel to the walls.

The service pipe and sleeve shall be constructed and installed to prevent gas passing along the space
between the pipe and the sleeve, and between the sleeve and the wall or floor so as to allow normal
movement of the pipe, e.g. a flexible seal between the pipe and the sleeve at each end. Whatever route is
chosen, pipes must be properly clipped and supported clear of the wall.

8.0 INSTRUMENTATION

8.1 Control Systems

Before fitting a pressure regulator on to a full cylinder ensure that the pressure adjusting screw is screwed
out so that there can be no flow through the regulator when the cylinder valve is opened.

Left-hand threaded pressure regulators should not be interchanged between gases, also left-hand to right
adaptors should not be used.

To prevent flames travelling back into cylinder, flashback arrestors shall be fitted downstream of pressure
regulators in oxygen, acetylene, propane and hydrogen systems. Where cylinders are connected to a
manifold or header, the system shall be fitted with one or more pressure regulators.

8.2 Hardware

The pressure regulators used shall be designed for use with high pressure gas cylinders, also it shall be
ensured that the threads are the same as on the valve outlet.

For prevention of back flow, a non-return or check valve shall be fitted. A more reliable alternative is the
fitting of an automatic shut-off/isolation valve. The shut-off action is activated by a low pressure signal
when the supply gas cylinder pressure reaches a level that requires the cylinder to be replaced.
 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 11 of 13
Rev 0 1999
9.0 SAFETY SYSTEMS

9.1 Safety Equipment

When a pressure regulator is fitted with pressure gauges, these shall not be removed, exchanged or
tampered with in any way. If a gauge leaks, the entire pressure regulator shall be returned to the
Vendor/Contractor.

The best quality hose, such as those required by supplier specification shall be used at all times.

Rubber hoses and hose assemblies for LPG cylinders of pressure up to 360 psig (2500 kPag) shall be in
accordance with BS 1762, or approved equal.

Flashback arrestors shall be used. This device is designed to quench the flashback and when it incorporates
a cut-off valve will automatically shut-off the gas flow.

9.2 Safety Procedures

The following safety procedures shall be followed, as applicable:

a) excessive heat on cylinders shall be eliminated by sun shade or other design dependant on
location;

b) electrical welding shall not be allowed to touch or get near to cylinders, (an accidental arc
between the tool and cylinder could overheat the cylinder wall);

c) cylinder valves should be kept clean, free from grit, dirt, oil or dirty water, if not leakage may
occur;

d) cracking open and immediately closing of a hydrogen cylinder valve to remove dirt or residual
moisture, should never be carried out as the hydrogen may ignite spontaneously;

e) cylinders shall be kept free from oil and grease at all times, likewise jointing compounds shall not
be applied;

f) with valve operation, use care, not force, (valves shall be opened slowly using the correct spindle
key, not subject to excessive torque). An opened valve shall never be left against the backdrop,
but shall be turned back at least half a turn to avoid seizure in an open position;

g) regular checks for faults and leaks shall be carried out, with special attention to pressure
regulators, (cylinders shall be checked for leaks both when they are in store and when they are
assembled with equipment for use. Special attention shall be paid to all joints and blowpipe
valves. Those assemblies which show any sign of deterioration shall be discarded);

h) frozen regulators or valves, caused by excessive flow rates shall be thawed with hot water, never
by flame.

9.3 Leak Detection

Cylinders shall be inspected regularly for leakage.

Never attempt to find a leak by means of a naked flame.

 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 12 of 13
Rev 0 1999

Leakage can be detected in any of the following ways given below:

(a) by means of smell (do not inhale);

(b) by sound of escaping gas;

(c) by condensation or frosting round the leak;

(d) leaks may be confirmed by brushing soapy water over the suspected leak source.

If a gas leak is suspected:

(a) do shut all valves on tank or cylinders and impacted control valves and facilities outside the
building;

(b) do open all doors and windows;

(c) do ventilate at floor level and low level areas and cellars (LPG is heavier than air);

(d) do not operate electrical switches - on or off;

(e) do not smoke or use naked flames and make sure that there are no other sources of ignition in the
immediate area.

9.4 Fire

The following actions shall be taken as appropriate in the event of a fire being discovered:

(a) follow company fire/safety procedures;

(b) evacuate the area to a safe location in accordance with company safety procedures;

(c) call the fire brigade;

(d) advise persons in the working area of the cylinder to relocate to a safe location in accordance with
company safety procedures;

(e) only trained personnel should attempt to fight the fire with the correct extinguishing agent;

(f) when the fire brigade arrives inform them of the location and number of gas cylinders directly
involved in the fire, and the names of the gases they contain;

(g) cylinders which are not directly involved in the fire and which have not become heated should be
moved as quickly as possible to a safe location, provided this can be done without any risk to
personnel.

Any cylinders which have been exposed to excessive heat, should be clearly marked.
 GENERAL ENGINEERING SPECIFICATION GES H.12
HP CYLINDERS STORAGE AND HANDLING Page 13 of 13
Rev 0 1999

10.0 PRIOR TO SHIPMENT

10.1 Painting and Coatings

Surface preparation, painting and painting materials shall be in accordance with GES X.01, GES X.02,
GES X.03.

10.2 Spares

The Vendor/Contractor shall submit with his proposal a priced list of recommended spares for start-up and
two years operation for review by Owner.

10.3 Packing and Storage

This section describes the minimum requirement for the preservation and protection of the equipment
during sea and land transportation and storage, prior to installation.

The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24
months shall be assumed. Packing to be suitable for sea freight.

(a) After mechanical completion at the works, the equipment shall be left in a clean dry condition.

(b) The Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent
damage during shipment.

(c) Machined or threaded exterior surfaces shall be protected during shipment and subsequent storage
with a rust preventer which is easily removed with a petroleum solvent.

(d) Threaded end connections shall be fitted with metal, wood or plastic plugs or caps.

(e) Flanges shall be protected over the entire flange surface by protectors which are securely attached
to the flange.

10.4 Shipping

Detailed shipping arrangements are covered by the Purchase Order/Contract.

The equipment shall not leave the Vendor/Contractor's works for shipment until the release has been
approved by the Owner's Inspector.

10.5 Warranty

The Vendor/Contractor shall warrant all materials and services supplied against any defect for a minimum
of twelve (12) months after commissioning or twenty-four (24) months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES J.16

INSTRUMENT CABLE AND CABLING

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 2 of 28
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4
1.3 Data Sheets 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Cables 9
3.3 Cable Glands 11
3.4 Junction Boxes 12
3.5 Cable Trays/Ladders 13
3.6 Cable Drums 13

4.0 MATERIALS 13

4.1 Cables 13
4.2 Cable Glands 13
4.3 Junction Boxes 13
4.4 Cable Trays 13
4.5 Cable Drums 14

5.0 MANUFACTURE 14

5.1 QA/QC 14
5.2 Identification and Labelling 14

6.0 INSTALLATION 16

6.1 Cables 16
6.2 Cable Routing 16
6.3 Cable Segregation 17
6.4 Cable Trenches 18
6.5 Trays and Supports 18
6.6 Junction Boxes and Termination 19
6.7 Cable Glands 19
6.8 MICC Cable 19
6.9 Conduit Sealing 19
6.10 Earthing 19
6.11 Installation of Network Cable and Components 19
6.12 Intrinsically Safe (IS) Circuits 21
 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 3 of 28
Rev 0 1999
SEC TITLE PAGE

7.0 INSPECTION 21

7.1 Procedures 21
7.2 Scope 22
7.3 Tagging Identifications 22
7.4 Cable Installations Inspection 22
7.5 Cable Glands 22

8.0 TESTING 22

8.1 Factory Testing 22

8.2 Site Testing 23

9.0 DOCUMENTATION 24

9.1 Introduction 24
9.2 Schedules and Reports 24
9.3 Data and Calculations 24
9.4 Drawings 25
9.5 Final Records, Documents and Manuals 25

10.0 PRIOR TO SHIPMENT 26

10.1 Packing and Storage 26

10.2 Shipping 26
10.3 Warranty 26

Table 2 Typical Petroleum Facility Cable Types Specification 27

Figure 1 Selection of Flameproof Glands based on BS 5345, Part 3 28

DATA SHEET (1)

 GENERAL ENGINEERING SPECIFICATION GES J.16
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Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the design, selection, specification, inspection,
testing, installation, documentation and preparation for shipment of instrumentation cables and associated
equipment. This specification does not cover instrument power supply cable or wiring.

1.1.2 The specification applies to equipment for refineries, onshore oil and gas installations and processing
facilities including items purchased either directly or as part of a package. This specification does not
cover instrument power supply cable or wiring or drilling area cables.

1.1.3 The specific cable details in this specification refer to cable normally used in petroleum facilities i.e. cable
to BS 5308 Part 1. Reference should be made to BS 5308 Part 2 for cable suitable for petrochemical
facilities. Cable and conduit systems supplied to other standards shall be supplied and installed in
accordance with the appropriate North American standards listed in this specification.

1.1.4 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception shall be authorised in writing by the Owner. The Vendor/Contractor may offer cables of his
standard manufacture which are equal or better than those required by this specification and where such an
alternative would offer a cost or delivery benefit to the Owner.

1.1.5 In the event of any conflict between this specification, or with any applicable codes and standards, the
Vendor/Contractor shall inform the Owner in writing and receive written clarification before proceeding
with the work.

1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

The following NOC Specifications are an integral part of this specification and any exceptions shall be
approved in advance by the Owner.

GES A.06 Site Data

GES C.55 Field Installation, Calibration and Testing of Instruments

GES J.01 Standard Instrument Symbols and Tags

GES J.12 Indoor Control Panels and Cabinets

GES J.13 Field Panels and Junction Boxes

GES J.17 Earthing of Instrument Systems

GES L.35 Electrical Equipment in Hazardous Area

1.3 Data Sheets

The technical data for each cable shall be specified on the Data Sheet(s). A typical project specific cable
specification for an oil field facility is attached. Project specific cable specification and Data Sheets for
each type of cable shall be developed for every project or facility.

2.0 DEFINITIONS

2.1 Technical
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The technical terms used in this specification are defined as follows:

Cable categories referred to in this specification are as defined in BS 6739, Section 10.7.2.

Category 1

Instrument power and control wiring (above 50V):

This group includes AC and DC power supplies and control signals including emergency shutdown control
circuits.

Category 1 may be considered for larger than normal cabling runs for control or shut-down circuits. Any
cable having a total loading of more than 10A shall be regarded as a power cable and is excluded from this
classification.

Category 2

High level signal wiring (5V to 50 V DC) - This group includes alarm signals, shutdown signals and high
level analogue signals e.g. 4 - 20 mA.

Category 3

Low level signal wiring (below 5V DC) - This group includes temperature signals and low level analogue
signals e.g. RTD, thermocouple signals.

2.2 Contractual

The commercial terms used in this specification are defined as follows.

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Vendor/Contractor to do part of the work awarded to the

Vendor/Contractor.
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Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

Instrument Cable and Cabling shall be manufactured, tested, installed and shall conform to the following
Codes and Standards:

The requirements specified herein are based on the IEC/British Standards Codes and Standards which are
listed below. Unless otherwise stated, equipment and materials shall comply with these IEC/BS Codes and
Standards.

This specification is based on the use of multicore cable rather than the use of conduits. Equipment and
materials complying with North American standards shall be at least equal to the requirements of this
specification. The Vendor/Contractor shall advise full details of any deviations to those requirements in his
offer if North American standards are proposed.

American Society for Testing of Materials (ASTM)

ASTM D 2863 Method for Measuring the Minimum Oxygen Concentration to Support Candle-
like Combustion of Plastics (Oxygen Index)

British Standards Institution (BSI)

BS EN 10095 Heat Resisting Steel and Nickel Alloys

BS EN 10257-1 Zinc or Zinc Alloy Coated Non-Alloy Steel Wire for Armouring either Power
Cables or Telecommunication Cables - Land Cables

BS EN 50267-1 Common Test Methods for Cables Under Fire Conditions - Tests on Gases
Evolved During Combustion of Materials from Cables-Apparatus

BS 801 Specification for Composition of Lead and Lead Alloy Sheaths of Electric
Cables

BS 2782 Methods of Testing Plastics

BS 3858 Specification for Binding and Identification Sleeves for Use on Electric Cables and Wires

BS 4066, Part 3 Tests on Electric Cables under Fire Conditions - Tests on Bunched Wires or
Cables

BS 4937 International Thermocouple Reference Tables - Platinum 10% Rhodium - Platinum

Thermocouples Type S
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BS 5308, Part 1 Instrumentation Cables: Specification for Polyethylene Insulated Cables

BS 5308, Part 2 Instrumentation Cables: Specification for PVC Insulated Cables

BS 5467 Specification for 600/1000V and 1900/3300V Armoured Electric Cables having
Thermosetting Insulation

BS 5501 Electrical Apparatus for Potentially Explosive Atmospheres

Part 1 - General Requirements

Part 3 - Pressurised Apparatus "p"

Part 5 - Flameproof Enclosure "d"

Part 6 - Increased Safety "e"

Part 7 - Intrinsic Safety "i"

BS 5099 Specification for Spark Testing of Electric Cables

BS 5345 Code of Practice for the Selection, Installation and Maintenance of Electrical Apparatus
for use in Potentially Explosive Atmospheres

Part 1 - General Recommendations

Part 3 - Installation and Maintenance Requirements for Electrical Apparatus

with Type of Protection "d" Flameproof Enclosure.

Part 4 - Installation and Maintenance Requirements for Electrical Apparatus

with Type of Protection "i" Intrinsically Safe Electrical Apparatus and
Systems.

Part 5 - Installation and Maintenance Requirements for Electrical Apparatus

with Type of Protection "p" Continuous dilution and for Pressurised
Rooms.

Part 6 - Installation and Maintenance Requirements for Electrical Apparatus

with Type of Protection "e" Increased Safety.

BS 6121 Mechanical Cable Glands

Part 1 - Specification for Metallic Glands

BS 6207 Mineral Insulated Cables with a Rated Voltage not exceeding 750V.
Part 1 - Cables
Part 2 - Terminations

BS 6234 Specification for Polyethylene Insulation and Sheath of Electric Cables

BS 6346 Specification for 600/1000V and 1900/3300V Armoured Electric Cables having PVC
Insulation

BS 6360 Specification for Conductors in Insulated Cables and Cords

BS 6708 Flexible Cables for Use at Mines and Quaries

BS 6739 Instrumentation in Process Control Systems: Installation Design and Practice

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BS 6746 Specification for PVC Insulation and Sheath of Electric Cables

BS 6883 Elastomer Insulated Cables for Fixed Wiring in Ships and on Mobile and Fixed Offshore
Units - Requirements and Test Methods

Energy Industry Council (EIC)

CCI P/4 Specification for Colour Coding of Instrument Signal Cables

CCI P/7 Specification for Instrument Cable Numbering and Junction Box Identification

International Electro Technical Committee (IEC)

IEC 600092, Part 3 Electrical Installations in Ships - Cables (Construction, Testing and Installations)

IEC 60331 Fire-resisting Characteristics of Electric Cables

IEC 60332, Part 3 Tests on Electric Cables under Fire Conditions - Tests on Bunched Wires or
Cables

IEC 60540 Test Methods for Insulations and Sheaths of Electric Cables and Cords
(Elastomeric Thermoplastic Compounds)

IEC 60754 Test on Gases Evolved During Combustion of Electric Cables - Determination
of the Amount of Halogen Acid Gas

IEC 947-1 Low Voltage Switchgear and Controlgear

American Petroleum Institute (API)

API 540 Electrical Installations in Petroleum Processing Plants

API 552 Transmission Systems

Factory Mutual Research Corporation (FM)

FM 3615 Explosion-proof Electrical Equipment

Instrument Society of America (ISA)

ISA 12.1 Definitions and Information Pertaining to Electrical Instruments in Hazardous

(Classified) Locations

ISA RP 12.4 Pressurised Enclosures

ISA RP-12.6 Wiring Practices for Hazardous (Classified) Locations Instrumentation -

Part 1: Intrinsic Safety

ISA S 12.12 Non-Incendive Electrical Equipment for use in Class I and II, Division 2 and
Class III, Divisions 1 and 2, Hazardous (Classified) Locations

National Electrical Manufacturer's Association (NEMA)

NEMA ICS 6 Industrial Control and System Enclosures

NEMA 250 Enclosures for Electrical Equipment (1000V maximum)

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National Fire Prevention Association (NFPA)

NFPA 70 National Electrical Code (NEC)

Article 300-384 Wiring Methods and Materials

Article 500-510 Special Occupancies
Article 700-770 Special Conditions
Article 800 Communication Systems

NEC/NFPA National Electrical Code Handbook

NFPA 496 Purged and Pressurised Enclosures for Electrical Equipment.

NFPA 497B Recommended Practice for the Classification of Class II Hazardous (Classified)
Locations for Electrical Installations in Chemical Process Areas

NFPA 499 Recommended Practice for the Classification of Combustible Dusts and of
Hazardous (Classified) Locations for Electrical Installations in Chemical Process
Areas

Underwriters Laboratories (UL)

UL 698 Industrial Control Equipment for use in Hazardous (Classified) Locations.

UL 886 Outlet Boxes and Fittings for use in Hazardous (Classified) Locations.

UL 1203 Explosion-proof and Dust-Ignition-Proof Electrical Equipment for use in

Hazardous (Classified) Location.

3.2 Cables

3.2.1 The cable will be subjected to salty atmospheres (costal areas only), long term direct sunlight, artificial
light and to light hydrocarbon gas contaminated atmosphere. The Vendor/Contractor shall warrant the
cables against deterioration for all the conditions above and as detailed in GES A.06.

3.2.2 The basic cable design shall be in accordance with BS 6739 Section 10.7 and shall be suitable for above
ground or direct buried installation.

3.2.3 Cables specified for the petroleum facilities shall be polyethylene insulated to BS 5308 Part 1. Cables
specified for chemical and petrochemical facilities shall be PVC insulated to BS 5308 Part 2. This
specification generally refers to the requirements for petroleum facilities.
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3.2.4 For petroleum facilities, cables shall be constructed generally in accordance with the requirements of BS
5308 Part 1 Type 2 (polyethylene insulation and PVC sheathing) and shall comply with the reduced flame
propagation requirements of BS 4066 Part 3 Category NMV3 and IEC 60332 Part 3 Category B for
bunched cables. Cable bedding shall preferably be polyolefin for improved flame retardancy but PVC
bedding may also be proposed.

3.2.5 Instrument cables used within buildings for interconnection between control systems in safe locations shall
be low emission reduced toxicity type, unarmored and constructed generally in accordance with BS 5308
Part 1 Type 1 (polyethylene insulation and PVC sheathing) and shall comply with the reduced flame
propagation requirements as stated in 3.2.4 above.

3.2.6 For petroleum facilities, all cables used in safety selected applications e.g. emergency shutdown and fire
and gas systems shall be constructed generally in accordance with BS 5308 Part 1 Type 2 and comply with
the fire resisting characteristics of IEC 60331.

3.2.7 The multipair cable core quantities shall be related to minimise the number of cable types on site. The total
multipair cable core quantity to a junction box shall be at least 125% of the installed single pair field
cabling to that junction box. No single multipair cable to a field junction box shall be more than 90% used.
All cores of all multipair cables shall be terminated. Multipair signal cables shall incorporate a single
telemetry pair as an option. Such requirements shall be specified on a project basis.

3.2.8 Unless otherwise specified all field cables shall be supplied with single wire galvanised steel armour.
However braided armour or interlocked galvanised steel type armour may also be specified. A proofed
tape shall be provided between the inner sheath and the armour.

3.2.9 Thermocouple extension cables shall be to BS 4937 individually screened, twisted (6 twists per foot) pair
or multipair compensating cables, incorporating drain wires to the following specification:

Copper Constantan for types K and type T thermocouples

Copper for type B thermocouples (where the cold junction temperature does not exceed 100°F (38°C)

3.2.10 Except for thermocouple cables, conductors for all cables shall be tinned annealed stranded coppers. For
thermocouple cables, the conductors shall be stranded and in the material specified. The number of cable
strands and conductor cross sectional areas are given in Table 1.

Table 1: Cable Strands and Cross Sectional Areas

No. of Cable Strands Diameter (mm) Area (mm2)

Field Run Multipair 7 min 0.43 1.0
Single Pair/Triplets 7 min 0.53 1.5

Control Buildings 16 0.2 0.5

System Cable 14 0.2 0.43

3.2.11 Consideration shall be given to the use of CSP (instead of PVC) for bedding and jacket (sheath) materials
for below ground cable. Also the use of lead sheathing to BS 801 (BS 5308 Type 3 cable) for areas of very
high hydrocarbon spillage risk.

3.2.12 Cable oversheathing colouring shall withstand the effects of direct sunlight, ultraviolet light and ozone.

3.2.13 Signal cables shall have overall collective screen only, the exception being cables for category 3 low level
signals; which shall have individual pair or individual triple (triad) screen.

3.2.14 Before ordering, the Vendor/Contractor shall submit to the Owner calculations showing the following:
 GENERAL ENGINEERING SPECIFICATION GES J.16
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1. That the voltage drop produced at the design current and over the design length is suitable for the
equipment being connected. The cable cross sectional area may be increased from 1.5mm² to 2.5
mm2 in order to meet the volt drop criteria.

2. That the cable parameters including L/R ratio and total loop capacitance are suitable for the total
loop integrity when used in conjunction with an Intrinsically Safe (I.S.) barrier. Matching with the
total I.S. loop parameters as dictated by the requirements of the system certificate shall be a fully
documented. The calculations shall be submitted to the Owner for approval prior to cable
purchase.

3. That the cable is suitable for the functional and service conditions specified and any special
requirements of particular instruments.

3.2.15 Subject to the Owner's approval mineral insulated cable (MICC) and glands may be used generally within
buildings on safety related applications such as the fire and gas detection system. MICC cable shall have
solid copper conductors with copper sheath and PVC oversheath. Cable cross sectional area shall be 1.0 or
2.5 mm2.

3.2.16 MICC cable shall be 2, 3, 4 or 7 cores with copper sheath and PVC oversheath in accordance with BS 6207
Part 1.

3.2.17 The use of compensating cable to connect thermocouple elements to remote read-outs or control stations
shall be avoided. Head or locally mounted amplifiers shall be used wherever possible. In cases where this
is not possible, individually screened twisted pair or multipair compensating cables incorporating drain
wires to the specifications listed in 3.2.9 shall be specified.

3.2.18 Cable subject to oil splash shall be supplied in accordance with IEC 60092 (similar to BS 6883) and shall
have enchanced oil resistance. Sheathing material type (A, B, or D) shall be decided on the application
basis but Type A will be considered acceptable in most cases.

3.3 Cable Glands

3.3.1 For standardisation purpose, certified EEx"d" or EEx "e" glands shall be used throughout hazardous and
non-hazardous field locations and industrial glands inside buildings in safe locations.

3.3.2 Electrical cables circular in cross section, compact in construction and manufactured to BS 5308, BS 5467,
BS 6708, BS 6883 and to BS 6346 with extruded bedding (not taped bedding) and non-hygroscopic fillers
shall be considered to be "effectively filled". These cables shall be assumed to be resistant to the
transmission of combustible gases and hence may or may not require barrier glands depending on the
circumstances. "Not effectively filled" cables in hazardous locations shall be fitted with barrier glands.

Barrier glands shall be used as dictated by the requirements of BS 5345 part 3 shown in Figure 1. The use
of barrier glands shall require Owner's approval.

3.3.3 The main guidelines for the selection of flame proof glands are as follows.

For mineral insulated cables in hazardous locations certified flameproof "pyro" glands shall be used.

All "non-effectively filled" cables shall require barrier glands.

"Effectively filled" cables shall not be fitted with barrier glands if:

a. The enclosure does not contain sparking or hot components,

or
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b. The enclosure is in a IIA or IIB gas in a Zone 2 area.

or

c. The enclosure is in a IIA or IIB gas in a Zone 1 but the volume of the enclosure is less than 2
litres.

Should the flameproof apparatus have its own certified cable entry devices e.g. an in line plug, then a
"filled" cable may enter straight into this device.

3.3.4 Additionally barrier glands shall be considered:

1. Where `cold flow' of cable insulation in considered a possibility. This is not an issue with
thermoplastic, thermosetting or elastomeric cable sheaths.

2. To prevent the possibility (where existing) of gas migration from one area to another.

3. To prevent moisture migration possibility (where existing) in cables.

4. Where the Owner considers a barrier gland essential for safety reasons.

3.3.5 All glands shall comply with the requirements of BS 6121 part 1, BS 5501 Part 1, 5 and 6 and other
standards as applicable.

3.3.6 Glands shall be suitable for PVC sheathed, extruded bedded, steel wire armour or steel wire braid (and
where specified for lead sheathing) for buried cable, and unarmored cable to BS 5308 Part 1 Type 2 and
Type 3.

3.3.7 Cable glands shall be CENELEC/BASEEFA certified for the hazardous area where specified.

3.3.8 Glands shall adequately grip the inner and outer sheath to provide a degree of protection to IP 66 minimum.
The gland thread shall be ISO metric 1.5 mm constant pitch.

3.3.9 Cable gland dimensions shall be compatible with the cable dimensions.

3.3.10 The glands shall be supplied complete with the accessories as specified on the gland schedule. Such
accessories shall be seals, sealing compound, rubber gloves, locknuts, serrated (earth continuity) washer or
tags and insulated adaptors.

3.3.11 Insulating adaptors on cable glands shall have the same size entry threads as the specified gland.

3.4 Junction Boxes

3.4.1 Refer to GES J.12 and GES J.13.

3.4.2 Splices are not permitted in wiring. When wiring must be extended, connections shall be made via terminal
blocks in a junction box installed above ground.
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3.5 Cable Trays/Ladders

3.5.1 All above ground cable runs shall be adequately supported on 180 microns thick galvanised return flange
cable tray or ladder manufactured from corrosion resistant steel to BS EN 10095 and installed in
accordance with the manufacturer's recommendation.

3.5.2 The tray shall be perforated, heavy duty with return flanges and shall be supported by steelwork using deep
galvanised proprietary support materials to minimise the effect from atmospheric corrosion. Additionally,
supporting brackets which are welded, screwed or bolted shall be thoroughly cleaned and protected using
etching primer and two coats of epoxy paint finish.

3.6 Cable Drums

All cable lengths shall be calculated by the Vendor/Contractor. The cable schedule shall include the
reference to the allocated drum. The length of cable on each drum shall be calculated to include the
allocated designed lengths and the cutting allowance so that all cables are available in continuous lengths.
Splicing or joining of cables is not permitted. Cables shall be measured prior to cutting of the cable by the
Vendor/Contractor.

4.0 MATERIALS

4.1 Cables

4.1.1 Typical cable materials are outlined in Table 2 attached to this specification.

4.1.2 In areas of high hydrocarbon spillage risk all cables installed underground shall be lead sheathed type
unless otherwise agreed in writing by the Owner .

4.2 Cable Glands

4.2.1 Cable glands, ground tags, lock nuts and washers shall be brass, nickel plated and shrouded for exposed
outdoor environment.

4.2.2 For area of high corrosion e.g. presence of H2S, gland material shall be 316 SS, shrouds shall not be used.

4.2.3 Sealing washers shall be Nylon 66 or equal. Shrouds shall be from polychloroprene or equal weatherproof
material.

4.3 Junction Boxes

4.3.1 Refer to GES J.13. Terminal boxes carrying critical duty circuits installed in high fire risk areas shall be
considered for fire protection.

4.4 Cable Trays

4.4.1 Cable tray or ladder racking material shall be in accordance with the Owner's specification.

4.4.2 In the absence of specific project requirements, cable tray or ladder rack material shall be of hot dipped
galvanised steel. The use of fire resistant cable trays in high fire risk areas shall require Owner's approval.

4.4.3 Plastic cable ties shall not be used. Clips, saddles and strapping used for securing cables to steelwork or
trays shall be metal with plastic coatings.

4.4.4 For areas having highly corrosive atmosphere e.g. presence of H2S stainless steel cable tray shall be used.
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4.5 Cable Drums

Cable drums shall be of wooden construction, fitted with steel reinforcing plates and be suitable for
packing and battening to provide protection during transportation and delivery.

5.0 MANUFACTURE

5.1 QA/QC

5.1.1 The Vendor/Contractor shall submit to the Owner, for approval, details of his proposed quality assurance
and Quality Control Plan.

5.1.2 The installation Contractor shall likewise be required to submit to the Owner for approval, details of his
proposed quality assurance and quality control plans.

5.2 Identification and Labelling

5.2.1 Cables

(a) Cable inner and outer sheath colours shall be light blue for intrinsically safe circuits and dark grey
(preferrred) or black for non-intrinsically safe circuits.

(b) The cable shall be identified through its length with the manufacturer's "Trace" code in
accordance with BS 5308 Parts 1/2 Section 4 paragraph 20.

(c) The cable oversheath shall be embossed in accordance with BS 5308 Parts 1/2 Section 4
Paragraph 21.2 and with customer type code.

(d) Fire resistant cables shall be embossed on the outer sheath with the word "Fire Resistant" at a
minimum 3 feet (1 m) intervals, continually along the cable length.

(e) Unless otherwise stated instrument signal colour coding shall be in accordance with CCIP/4. The
following system may also be utilised. Core identification shall be by solid contrasting colours as
follows:

Pair White (negative polarity), Black (positive polarity) with number code on
polyester tape.

Triad White, Black, Red with number code on polyester tape.

Quad White, Black, Orange, Green with number code on polyester tape.

Thermocouple Extension cable: Positive white, negative blue to BS 4937

(f) A cable marker system shall be used to identify the cables, of a type to be agreed with the Owner.
Preferably the printer ribbon shall use indelible ink which dries quickly, does not smear or fade or
run when exposed to UV light, weathering or solvents.

(g) All wires and cables shall be identified using a project specific numbering system. In the absence
of a specific numbering system the Vendor/Contractor shall base his system on the requirements
of Energy Industry Council (EIC) document CCI P/7. See also GES J.01.

(h) The individual conductors of extension cables shall be colour coded in accordance with BS 4937.

5.2.2 MICC Cable

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a) A system of identifying the MICC Cable cross sectional area, number of cores and cable sheath
colour shall be developed by the Vendor/Contractor.

b) MICC cable sheath colour shall be blue for fire and gas system intrinsically safe circuits and red
for non-intrinsically safe circuits.

5.2.3 Junction Boxes

For identification of junction boxes see GES J.13.

5.2.4 Cable Glands

A project specific identification system for the cable glands shall be developed by the Owner. This system
shall utilise a combination of digits and letters to identify the type of gland, nominal gland size, actual
gland size within the manufacturer's range to fit the cable type specified and the gland accessories e.g. earth
tags etc. The Vendor/Contractor shall utilise this system to identify the individual gland for its suitable
cable.

5.2.5 Cable Drums

(a) Each cable drum shall have a waterproof and clearly marked identification label permanently fixed
to each flange. The label shall be 12"x 8" (300 mm x 200 mm) and shall carry the following
information in 3/8 inch (9.5 mm) high characters.

1. Drum number (coded if applicable)

2. Cable type number (if allocated)
3. Voltage grade
4. Cable length
5. Purchase Order/Contract number
6. Cable construction
7. Number of cores and cross sectional area
8. Total weight of cable and drum
9. Manufacturer and Date

(b) In addition to the above, each cable drum flange shall be clearly marked in 2" (50 mm) high
characters the following information:

1. Drum number (coded if applicable)

2. Cable type number (if allocated)
3. Purchase Order/Contract number
4. Weight
5. Manufacturer and date

5.2.6 Cable Trenches

(a) Concrete cable route markers buried over the cable protection tiles shall be positioned at 25 feet
(8 m) intervals on straight runs and, at route change points and at intersections. For trenches with
width greater than 3 feet (1 m) the markers shall be provided on both sides of the trench.
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(b) Concrete markers shall be sulphate resistant and shall have miniumum crushing strength of 2000
lb/in2 at 28 days. Markers shall be 2" (50 mm) and 10" (250 mm) above and below grade
respectively.

(c) A marker tape shall be laid 12" (300 mm) above the cable. The tape shall be made of non-
degradable material, shall be 6" (150 mm) wide and shall carry the legend "INSTRUMENT
CABLE BELOW" in both English and Arabic

6.0 INSTALLATION

6.1 Cables

6.1.1 Multicore cable shall not be bent during installation to a radius less than the manufacturer's recommended
"Minimum Bending Radius". This is typically 8 overall cable diameters.

6.1.2 Cable manufacturer's installation recommendations shall be followed if during installation an ambient
temperature of 0°C (32°F) is likely to be encountered.

6.1.3 Cable entering a "safe" area and originating from a hazardous area shall be pressure tight at the transition
point/wall. Such vapour tight seals shall also be provided where the cable enters or leaves an underground
pipe.

6.1.4 Cable run through pipes shall be smooth and burr free. Cable pulling through pipes shall be carried out in a
manner that will not damage the cable. Data link cables, and fibre optic cables and other specialised cables
shall be installed per manufacturer's recommendations.

6.1.5 Cable joints on cable tray, ladder racking or underground is not permitted. Only connections to approved
equipment, junction boxes or instrument terminals are permitted. All cables shall be installed and
terminated strictly in accordance with the documentation provided by the Owner.

6.1.6 Unless the cable is immediately glanded after cutting, the ends of the cable shall be effectively temporarily
sealed using a proprietary sealing cap.

6.1.7 Cable drum unloading shall be undertaken with hoisting equipment or with ramp boards, together with a
winch or a coil of rope around the drum.

6.1.8 The cable pulling rope shall be attached using a cable pulling stocking with double thimbles. If the load is
high then pulling eyes shall be used.

6.2 Cable Routing

6.2.1 Cable routing shall be in accordance with the cable installation and routing drawings.

6.2.2 Site-run cabling shall be routed bearing in mind the following; where possible, site runs shall:

1. Be kept as short as possible consistent with good practice and accessibility.

2. Not obstruct traffic through the process plant.

3. Do not interfere with the accessibility or removal of process equipment (e.g. pumps, motors
exchange bundles, etc).

4. Avoid hot environmental and potential fire-risk areas.

5. Not be subject to mechanical abuse (e.g. people stepping on it).

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6. Avoid areas where spillage is liable to occur (e.g. from overflowing tanks).

7. Avoid condensate drainage points.

8. Avoid areas where escaping vapour or corrosive gases could present a hazard.

9. Avoid process piping and are provided with sufficient clearance from piping which may require
lagging.

6.2.3 Cable routing shall be such that the physical protection afforded by structural steelwork is maximised.

6.2.4 In areas where the hazards stated in 6.2.2 can not be totally avoided, installing the cables within metal
conduits or trenching shall be considered. In high fire risk areas, additional protection in the form of
mineral wool with outer aluminium cladding, applied externally to the trunking, shall be considered.

6.2.5 Dual redundant data communications and such similar cables where installed overhead shall be routed
using separate paths. If buried, the duty and the standby cables may share the same trench since the
probability of damage is low. However, adequate segregation shall be maintained between the primary and
the backup cable in order to guard against exposure to damage. Such cable, if possible, shall enter cabinets
or consoles from opposite sides.

6.2.6 Cables inside a bund wall shall be routed above ground on cable trays.

6.2.7 Cables installed beneath raised type (computer type) floors shall be placed in a cable tray installed as close
as possible to the underside of the raised floor.

6.3 Cable Segregation

6.3.1 It is preferred that instrument cables above ground are run on dedicated cable trays and separate from
power cabling. If instrument and power cables run on the same cable tray or trench they shall be grouped
on opposite sides with a minimum separation distance as detailed below.

It is preferred that instrument cables above ground are run on dedicated cable trays and separate from
power cabling. If instrument and power cables run on the same cable tray or trench they shall be grouped
on opposite sides with a minimum separation distance as detailed below.

Separation of instrument and power cable on skids, cable tray or in cable trench shall be as follows:

125 V or 10A : 12 in (300 mm)

250 V or 50A : 18 in (450 mm)
440 V or 200A : 24 in (600 mm)
3.3 kV or 800A : 55 in (1400 mm)
11 kV or 1500A : 71 in (1800 mm)

6.3.2 All wires in the multicore shall carry signals of the same type and voltage level. Similarly, all multicores
routed by the same cable tray shall carry signals of similar type and voltage level.

6.3.3 Cables for turbine meters, analyser signals (not 4-20 mA), digital networks and thermocouple
compensating cables shall be separate.
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6.3.4 No segregation needs to be observed between thermocouple, millivolt pulse or 24V DC 4-20 mA signal
cables. However, a minimum of 1" (2.5 mm) distance shall be provided between the above signal types
and 24V DC and 48V DC signal cables. This distance shall be increased to 12" (300 mm) if the latter
voltage is increased to 125V DC.

6.3.5 Crossover of the instrument and power cable shall be avoided. Where this is not possible, the crossover
shall be at right angles to each other.

6.3.6 A minimum distance of 5 feet (1.5 m) between the instrument cable and electrical noise generating
equipment shall be maintained. Examples of such equipment are motors, generators, transformers, arcing
devices etc.

6.3.7 Where instruments are situated in remote locations and in close proximity to each other, different signal
types (e.g. category 2 - intrinsically safe analogue and digital circuits) may be combined in the same
multicore subject to the Owner's approval.

6.3.8 IS and non IS cables sharing the same cable trench shall be segregated using cable tiles on edge as
partition.

6.3.9 Where the thermocouple extension cables are run in a conduit, no other electrical or instrument wiring shall
run in the same conduit.

6.3.10 A minimum clearance of 12" (300mm) shall be maintained between cable and parallel run of underground
piping.

6.4 Cable Trenches

6.4.1 Buried cable depth shall be 30" (750 mm) for uncovered back filled trenches and 20" (500 mm) for
concrete-covered sand-filled trenches. A 6" (150 mm) and 4" (100 mm) (minimum thickness clean sieved
soft sand or other suitable cushioning material shall cover the top and bottom respectively of the cable. The
cable tile top shall have 6" (150 mm) wide green tape with message "CAUTION - INSTRUMENT CABLE
BELOW" printed on it. The layer shall be protected by concrete cable covers or earthenware and the
trench shall be back filled and compacted to restore the ground to its original grade and finish.

6.4.2 Alternative to the earthenware and concrete cable covers may be proposed by the Vendor/Contractor
subject to the Owner's approval.

6.4.3 Cable heat dissipation calculation check shall be carried out if multiple tiers of category 1 type instrument
cable installation is undertaken.

6.4.4 Metal sleeves, extending 6" (150 mm) below ground and 10" (250 mm) above ground, and encased in
concrete shall be used to protect cables from fire and mechanical damage where the cables leave the
trenches. Moisture ingress shall be prevented by the use of suitable sealing compound.

6.4.5 Cables shall not be installed under adverse weather conditions without the Owner's written approval.

6.5 Trays and Supports

6.5.1 Cables shall be supported and clamped on tray over their full length and shall be neatly run, adjacent to
structure and steelwork.

6.5.2 If required, cable trays shall be provided with additional support to prevent sagging if run in the horizontal
plane.
 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 19 of 28
Rev 0 1999
6.6 Junction Boxes and Termination

6.6.1 Refer to Specifications GES J.12 and GES J.13.

6.6.2 With the exception of special cables e.g. co-axial cables, cables for vibration monitoring, load cells, certain
analysis such as pH cables and thermocouple cables, all signal wiring shall be routed to a marshalling panel
terminal strip.

6.6.3 Separate junction boxes shall be used for analogue control cables, digital control cables, emergency
shutdown system cables, fire and gas detection system cables and intrinsically safe cables. Also refer to
Section 6.3.7.

6.6.4 Cables shall be terminated and ferruled in accordance with the design drawings and project specifications.
Sufficient cable slack shall be left at instruments and junction boxes to allow for remaking of connections.
Multicore cables at control panels shall be terminated at terminal strips.

6.6.5 Terminations shall be made with approved tools. Crimp-on terminals shall not be used on thermocouple
wires. Stranded conductors shall be fitted with crimped lugs in accordance with the project documentation.

6.6.6 Wiring cabling, glanding and termination methods shall be strictly in accordance with the requirements of
BS 5345.

6.6.7 All unused entries on field mounted junction boxes shall be fitted with a certified plug, washer and nut to
satisfy the requirements of BS 5345 Part 6 Clause 17.3.

6.6.8 Where possible and practical, plug-in type of connectors shall be used for interconnections between
marshalling panel terminals to control room instrumentation. Wiring lists identifying pin connections shall
be provided for each such pre-assembled cable.

6.6.9 Analyser and other special instruments requiring special cables and connectors shall be installed and
terminated in accordance with the manufacturer's instructions. Load cell cables are normally factory
matched for resistance and therefore shall not be cut. Any such or any similar factory matched cable, if in
excess length, shall be neatly coiled and tied in a well protected area.

6.6.10 A numbering system for the junction boxes, terminals, terminal rails and wire numbers shall be developed
per project basis based on GES J.01.

6.7 Cable Glands

6.7.1 EExd glands shall be used to gland EExd certified instruments and junction boxes and EExe glands shall be
used with EExe certified boxes. Industrial glands shall be used inside buildings in safe locations.

6.7.2 Barrier glands shall be fully filled using the correct filler compound.

6.7.3 EExe glands shall be installed with an earthing tag of adequate capacity to carry the maximum fault current.
Glands shall be provided with neoprene washer and dust seal to provide a seal to IP65 and to protect the
armouring from corrosion. Armour clamp shall be capable of withstanding pull test.

6.7.4 EExd glands shall be checked to ensure that the gland:

1. is correct for the hazardous area

2. has adequate threads to provide the correct tolerance flamepath

3. has correct number of threads and length for the gas group

4. does not have undercut threads

 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 20 of 28
Rev 0 1999

5. has inner seal that fits the cable properly

6. provides minimum seal length of 5mm

7. has an overall seal to stop ingress of moisture

8. the armour clamp can withstand the pull test.

6.8 MICC Cable

MICC cable sealing and terminations shall be made in accordance with the manufacturer's instructions and
BS 6207, Part 2.

6.9 Conduit Sealing

For equipment ordered to North American standards conduit and cable seals shall be installed in
accordance with NEC Articles 501-5 and 502-5. Reference shall be made to NEC Handbook.

6.10 Earthing

6.10.1 Refer to Specification, GES J.17.

6.10.2 For cable systems supplied to North American standards both safety earth and instrumentation circuit
ground shall conform to NEC, Article 250.

6.11 Installation of Network Cable and Components

6.11.1 System Vendor/Contractors recommendations shall be followed.

6.11.2 Before installation is undertaken the following checks shall be made

1. The cable duct or tray shall be checked for spare capacity.

2. The number and location of taps shall be determined.

3. The proposed route shall be surveyed for hazardous environment, sharp bends, areas of high
temperature, electrical radiation (including from fluorescent light strips) and heavy electrical
equipment.

4. The cable shall be checked for soundness using Time Domain Reflectometers (TDR's). A
hardcopy record of TDR shall be attached to the cable test certificate. Optical TDR may be
available and used as required.

5. All transceivers, repeaters, drop cables and connectors shall be tested before installation.

6.11.3 A cable puller shall be used with setting to avoid strain on the cable.

6.11.4 The cable maximum bending radius shall be taken into account when pulling the cable.
 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 21 of 28
Rev 0 1999
6.11.5 Special care shall be taken with fibre optic cables. Only personnel trained in this technology shall be
allowed to install these cables and make connections. Cable splicing shall be avoided wherever possible.
Where necessary precaution shall be taken to make sure that unacceptable level of signal loss does not
occur.

6.11.6 Where cable is spliced together with connectors, identical cable shall be used for splicing purposes.

6.11.7 Cable run records shall be updated after installation.

6.11.8 Cable shall be labelled at both ends using shrink ferrules and permanent markers.

6.11.9 When the appropriate connections are made to plugs, wall plate fittings, etc. a multimeter shall be used to
check for short circuits.

6.11.10 All transceivers shall be securely mounted and shall not hung from the cable.

6.11.11 Upon installation completion:

1. The cable structure shall be retested using a TDR and a hard copy of the record shall be retained.

2. A check for the existence of earth loops shall be performed.

3. Post installation checks shall include:

Checks to make sure that only proper size connectors have been used.

Checks that the connectors have protective shrink tubing.

6.12 Intrinsically Safe (IS) Circuits

6.12.1 Installation of IS circuits shall comply with the requirements of BS 5345 or NEC Article 504,
manufacturer's certificate, manual and control drawing.

7.0 INSPECTION

7.1 Procedures

7.1.1 The inspection requirements are covered by the "General Conditions of Purchase" which forms part of the
Purchase Order/Contract. Additional requirements are given below.

7.1.2 The Vendor/Contractor shall allow the inspector free access to all areas of manufacture, fabrication,
assembly, installation and testing.

7.1.3 The Vendor/Contractor has the responsibility to provide adequate quality control and inspection of
equipment and materials in accordance with QA/QC procedures. Any inspection by the Owner or his
Inspector shall not relieve the Vendor/Contractor of these responsibilities or those under his warranties.

7.1.4 The Vendor/Contractor shall submit the proposed test procedures for testing the cables, to the Owner for
approval, at least one month before the tests are due to start. The acceptance criteria for each test shall be
defined in the procedure.
 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 22 of 28
Rev 0 1999
7.1.5 Test procedures shall include for assuring that the pre-requisites for a given test have been met and that the
test is performed under suitable environmental conditions by appropriately trained personnel using
calibrated instrumentation with current test certificates.

7.1.6 The Vendor/Contractor shall notify the Owner at least one week in advance that the cables are ready for
test.

7.1.7 The Vendor/Contractor shall provide a written report, with a record of the readings taken at the test, and
appropriate test certificates and test logs included for review by the Owner.

7.1.8 Original of all test certificates shall be submitted to the Owner within one week of the completion of the
tests.

7.1.9 The cost of rectification and repair to cables of any defects found during inspection/testing shall be at the
Vendor/Contractor's sole expense.

7.2 Scope

The Vendor/Contractor shall provide details of his inspection and testing procedures and provide results of
specific tests.

7.3 Tagging Identifications

Cable tagging and Identifications shall be as detailed in Section 5.2.

7.4 Cable Installations Inspection

Prior to back filling, an inspection shall be carried out to check and confirm:

1. proper bedding of cables has been carried out

2. the correct spacing for cables in the same trench, tray or ladder has been allowed for

3. duct mouths are protected with suitably sized bushes to prevent damage and stop vermin entering

4. removal of pulling equipment is complete

5. installation has not caused any damage to the cable

6. the underside of the cable shall be inspected using a mirror.

7.5 Cable Glands

Cable glands shall be inspected in accordance with the requirements of Section 6.7.

8.0 TESTING

8.1 Factory Testing

8.1.1 The tests below are not necessary for small quantities of cable where certificates of conformity may be
considered acceptable, subject to the Owner's approval.
 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 23 of 28
Rev 0 1999
8.1.2 Should the selected cable sample fails a test, then at the discretion of the Owner and at Vendor/Contractor's
expense, retest on further cable samples shall be carried out. The cable shall be rejected if the cable fails to
meet the required acceptance criteria.

8.1.3 Testing shall be carried out on each drum.

8.1.4 All cables shall be tested in accordance with the requirements of BS 5308 Part 1 or BS 5308 Part 2 Section
3 as applicable.

8.1.5 Tests shall include, but not limited to:

1. Insulation resistance tests (of each conductor against remaining conductors, screens and armour).

2. Resistance, inductance and capacitance tests.

3. Voltage tests including spark test.

8.1.6 Test samples of flame retardant cables shall be randomly selected and tested to BS 4066 Part 3 Category
NMV3 and IEC 60332 Part 3, Category A or B as specified by the Owner.

8.1.7 Test samples of fire resistant cables shall be randomly selected and tested to IEC 60331 at a temperature of
1832°F (1000°C). In addition, a mechanical stress test and a water deluge test shall be agreed with the
Client.

8.1.8 When the cable is tested in accordance with BS EN 50267-1 (which is similar to IEC 60754 Part 1) the
acidic gas evolved during combustion shall be less than 0.5%.

8.1.9 The outer sheath and the bedding shall be tested in accordance with applicable codes and standards listed in
this specification. When tested in accordance with BS 2782 method 141D, the oxygen index of low
smoke/fume bedding and sheathing material of the assembled cable shall not be less than 30.

8.1.10 MICC cables shall be tested in accordance with the requirements of BS 6207 Part 1.

8.1.11 A check on the marking in accordance with the specification and the Purchase Order/Contract shall be
carried out.
8.1.12 A dimensional check of all cables and cable drums shall be carried out. A sample of each cable shall be
dissected and checked for correct dimensions, make-up of tapes, core colour, identification etc. These
checks shall include:

1. Measurement of insulation thickness and the thickness of inner and outer sheaths.

2. Measurement of diameter over inner and outer sheaths.

3. Measurement of wire diameter.

4. Measurement of weight per yard (m).

8.2 Site Testing

Site testing shall be carried out in accordance with the requirements of specification GES C.55.
 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 24 of 28
Rev 0 1999
9.0 DOCUMENTATION

9.1 Introduction

9.1.1 This section covers the documentation required for the design, selection, fabrication, installation, inspection
and testing of cables.

9.1.2 The detailed list of documents that are required is attached to the Purchase Order/Contract. However, as a
minimum the following listed documents shall be provided by the Vendor/Contractor:

- Cross sectional drawings

- Catalogue Data Sheet
- Installation instructions
- Qualitly Control Plan
- Weight information sheets
- Cable test procedures
- Special tools list
- Packing/storage requirements

9.1.3 The following data shall be supplied with quotation:

- Gland dimensions for comparison of cable inner and outer sheath dimensions and armour diameter
to demonstrate that these are as stated in the Data Sheet.

- Gland cross-sectional drawing detailing materials used.

9.2 Schedules and Reports

The Vendor/Contractor shall submit with his tender a preliminary Quality Control Plan.

9.3 Data and Calculations

The following information shall be supplied by the Vendor/Contractor for each type of cable:

- Conductor size mm2

- Number of cores/pairs/triples
- Maximum operating voltage V (rms)
- Rated voltage of cable insulation KV (rms)
- Maximum allowable continuous conductor
temperature °F (°C)
- Conductor material
- Continuous current rating in free air
ambient temperature A
(Ambient temp=130°F (54°C)
- Number of strands in conductor
- Diameter of the strands inches (mm)
- Resistance of conductor at 70°F (21°C) Ω/1000 ft (Ω/km)
- Inductive reactance at 50/60 Hz Ω/1000 ft (Ω/km)
- Capacitive reactance at 50/60 Hz Ω/1000 ft (Ω/km)
- Minimum insulation resistance MΩ
- Insulation grade
- Sheath grade
- Weight of cable lb/ft (kg/m)
- Insulation thickness inches (mm)
- Sheath thickness inches (mm)
- Armour/braid thickness inches (mm)
 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 25 of 28
Rev 0 1999
- Diameter over inner sheath (bedding) inches (mm)
- Overall diameter of cable inches (mm)
- Pair/triple screen
- Collective screen
- Minimum handling temperature °F (°C)
- Normal length of one drum yards (m)
- Weight of drum with cable (normal) lb (kg)
- Weight of drum with cable (maximum) lb (kg)
- Oxygen index overall
- Smoke density rating overall
- HCL emission level
- Cable/core marking details
- For IS cables, L/R ratio, mutual and
unbalanced capacitive reactance at 50/60 Hz.

9.3.2 The Vendor/Contractor shall supply proven data as part of the Purchase Order/Contract.

9.3.3 The cable data submitted and accepted by the Owner prior to Purchase Order/Contract placement may be
used for design purpose by the Vendor/Contractor. Any deviations from the data, after Purchase
Order/Contract placement, shall be subject to approval by the Owner.

9.4 Drawings

9.4.1 As-built layout drawings of all above ground and underground cable routings shall be furnished in
sufficient details and accuracy to serve as a record of the installation for maintenance purposes.
9.4.2 For underground cabling systems, the installation drawings shall specify the procedures to be followed in
the field to ensure that above ground markers, as finally installed, do accurately show underground cables.

9.4.3 A list of all above ground critical wiring circuits or sections of critical wiring circuits requiring fireproofing
shall be prepared by the installation Contractor for approval by the Owner. The list shall include:

(a) An identification of the possible source of sustained fire and the proximity to wiring.

(b) The length and location of each circuit requiring fire protection.

9.5 Final Records, Documents and Manuals

Two copies of the Data Dossier and six copies of the installation and maintenance manual shall be
supplied. The contents of the Data Dossier shall be agreed with the Owner but as a minimum shall include:

- Weight Test Certificates

- Inspection Release Certificates
- Code Compliance Certificates
- Component Certificate
- Hazardous Area Certificate
- Fire Test Certificates
- Test Reports
- Letters of Confirmity
 GENERAL ENGINEERING SPECIFICATION GES J.16
INSTRUMENT CABLE AND CABLING Page 26 of 28
Rev 0 1999
10.0 PRIOR TO SHIPMENT

10.1 Packing and Storage

10.1.1 This section describes the minimum requirements for the presevation and protection of cables and drums
during sea and land transportation and storage prior to installation.

10.1.2 The probable sorage period shall be specified in the Purchase Order/Contract and will extend from the time
of despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24
months shall be assumed.

10.1.3 Cables shall be drummed in maximum continuous lengths, unless the Owner has specified specific drum
lengths, in which case the Vendor/Contractor shall not change the drum lengths without the Owner's
written approval. Drums shall be non-returnable type. The maximum diameter of the cable drums, shall not
exceed 7 feet (2.1 m) without written of approval by the Owner.

10.1.4 Cable ends shall be sealed and fixed to the drum and shall be suitably protected against damage during
transportation and storage e.g. by the use of battens fitted around the entire periphery of the drum.

10.1.5 Each gland shall be individually packed with accessories as specified. The pack shall be securely fastened
containing all components and be clearly identified with the project part number.

10.2 Shipping

The cable drums and other material shall not leave the Vendor/Contractor's works for shipment, until the
release has been approved by the Owner's Inspector.

10.3 Warranty

10.3.1 The Vendor/Contractor shall warrant all cables under the Purchase Order/Contract against any defect, for a
minimum period of 20 years after commissioning, or for the 20 years after the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

10.3.2 The terms and conditions of the warranty shall be additional to any other requirements specified in the
Purchase Order/Contract.

10.3.3 Should any cable be found defective, the Vendor/Contractor shall be responsible for all costs associated
with replacing the cable to the standard specified by the Purchase Order/Contract.
 DATA SHEET No.

INSTRUMENT SIGNAL CABLES

P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 1 of 1
SERVICE ITEM No. No. of UNITS

1 VENDOR / CONTRACTOR
2
3 PURCHASE ORDER NO
4 Single/Multi Pair/Triple Above/Below Ground Signal/Solenoid Valve/Thermocouple Extension/MICC Cable
5
6 Type
7 Conductors
8 Core Grade
9 Grade Volts
10
11 Construction
12 Screen
13 Drain Wire
14
15 Overall Sheath
16
17
18 Lead Sheathing
19 Bedding
20 Armouring
21
22
23 L/R Ratio
24
25
26 Identification
27
28 Notes
29
30
31 All quantities in feet/yards/miles Minimum Drum Length
32 Item Cable Column 1 Column 2 Column 3
33 No Type Quantity Quantity Quantity
34
35
36
37
38
39
40
41
42
43
44
45
Revision No./Date
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
K:\nocspecs\SPECIFICATIONS\j-series\j-16\dj1601r0.xls Sheet1
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES J.17

EARTHING OF INSTRUMENT SYSTEMS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES J.17
EARTHING OF INSTRUMENT SYSTEMS Page 2 of 11
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Other NOC Specifications 3

2.0 DEFINITIONS 3

2.1 Technical 3
2.2 Contractual 4

3.0 DESIGN 4

3.1 Codes and Standards 4

3.2 Earthing (Grounding) Philosophy 5
3.3 Earth Bars 6
3.4 Safety Earth System 7
3.5 Instrument Earth and IS Earth Systems 8

4.0 INSTALLATION 10

5.0 TESTING AND INSPECTION 11

 GENERAL ENGINEERING SPECIFICATION GES J.17
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Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the design, material selection, installation,
inspection and testing of instrument earth systems.

1.1.2 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.3 In the event of any conflict between this specification and any applicable codes and standards, the
Vendor/Contractor shall inform the Owner and receive written clarification before proceeding with the
work.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification, and
any exceptions shall be approved in advance by the Owner.

GES B.01 Central Control Buildings

GES J.12 Indoor Control Panels and Cabinets

GES J.13 Field Panels and Junction Boxes

GES L.25 Grounding and Overvoltage Protection

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Earthing/Grounding

For the purpose of this specification, the terms earth and ground are synonymous and may be
interchanged as required.

Bonding

The permanent joining of metallic parts to form an electrically conductive path.

Instrument Earth (Clean ground)

Instrument earth is an earth connection provided to ensure that all components of a measuring/control
system are referenced to the same potential thus minimising the possibility interference (noise) on the
signal lines. The instrument earth is isolated from other earths other than at the final connection to the
plant earth to allow testing.

IS Earth (IS ground)

IS earth is an earth connection to provide a low impedance earth path for intrinsically safe cicuits in
accordance with the requirements of the equipment certification and applicable standards.

The IS earth is isolated from other earths other than at the final connections to the to the plant earth.
 GENERAL ENGINEERING SPECIFICATION GES J.17
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Rev 0 1999
Plant Earth (Plant ground)

Plant earth is an earth connection which is directly linked to the plant earthing system. This may be an
earth grid, the neutral of the supply transformer, or a combination of both.

Safety Earth (Dirty equipment/protective ground)

Safety earth is an earth connection provided for the protection of plant and personnel against electrical
faults, static electricity and lightning strikes. The safety earth is sized to allow the correct operation of
protective equipment.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and
facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a contractor to do part of the work awarded to the contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of
this specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verifies that the equipment and facilities have been designed, constructed, inspected
and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

3.3.1 The earthing design shall comply with this specification and the following codes and standards.
 GENERAL ENGINEERING SPECIFICATION GES J.17
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Rev 0 1999
3.3.2 Unless specified otherwise in the Purchase Order/Contract, the current editions of the codes and
standards at the time of the order shall be used.

American Petroleum Institute (API)

API RP 550 Manual on Installation of Refinery Instruments and Control Systems - Part 1
Section 7: Transmission Systems (being rewritten)

American National Standards Institute (ANSI)

ANSI C39.5 Safety Requirements for Electrical and Electronic Measuring and Controlling
Instrumentation

British Standards Institution

BS 1433 Specification for Copper for Electrical Purposes - Rod & Bar

BS 5345 Code of Practice for Selection, Installation and Maintenance of Electrical

(All Parts) Apparatus for Use in Potentially Explosive Atmospheres

BS 7430 Code of Practice for Earthing

BS 7671 Requirements for Electrical Installations

Canadian Standards Institute (CSI)

CSA C22.1 Canadian Electrical Code - Safety Standard for Electrical Installations

C22.2-157 Intrinsically Safe and Non-incendive Equipment for Use in Hazardous Locations

Instrument Society of America (ISA)

ISA RP 12.6 Wiring Practices for Hazardous (Classified) Locations Instrumentation -

Part 1: Intrinsic Safety

Nation Fire Protection Association (NFPA)

NFPA 70 National Electrical Code

NFPA 493 Intrinsically Safe Apparatus

Institute of Electrical and Electronics Engineers (IEEE)

IEEE 142 Recommended Practice for Grounding of Industrial and Commercial Power
Systems

3.2 Earthing (Grounding) Philosophy

3.2.1 General

(a) Instrument earth systems shall be provided to:

- minimise the hazards to personnel and equipment resulting from electrical faults,
lightning discharges and static electricity;

- reduce the effects of electrical interference on the signal lines of instruments;

 GENERAL ENGINEERING SPECIFICATION GES J.17
EARTHING OF INSTRUMENT SYSTEMS Page 6 of 11
Rev 0 1999
- to limit the energy transmitted to equipment located in hazardous areas (intrinsically safe
systems).

(b) The instrument earth system shall be made up from three independent sub-systems:

- A safety earth, to ensure that no significant impressed potentials exist on metallic

enclosures which would create a hazard to personnel and equipment.

- An instrument earth system, to ensure that all points within measuring or logical systems
are referenced to the same potential.

The following shall be connected to the instrument earth system:

- non IS cable screens;

- 0 Volt of signals for non-floating, non IS circuits (DC signal common);
- spare cores in non IS cables;
- DC power supply reference.

- An Intrinsic Safety (IS) earth system (if required), where the IS method of protection for
instruments in hazardous areas is used, to ensure that safety barriers can be connected to a
high integrity, low impedance earth required by intrinsically safe systems.

The following shall be connected to the IS earth system:

- IS cable screens;
- spare cores in IS cables;
- Zener barrier earths.

(c) As it is often difficult to obtain the specified earth resistance value throughout the year as soil
conditions may vary, a soil survey shall be undertaken to determine the resistance to earth value.
If required, a dedicated ground rod system with ground well, shall be provided. Depending on the
soil condition three rods delta connected or an earth mat shall be used. A project specific
grounding system detail shall be developed for Owner's approval.

3.3 Earth Bars

(a) All earth bars shall be fabricated from high conductivity, hard worked drawn copper in accordance
with or equivalent to the requirements of BS 1433.

(b) Panel cabinet earth bars shall have a cross section of 1 in x ¼ in (25 mm x 5 mm), and building
earth bars shall have a cross section of 1½ in x ½ in (35 mm x 10 mm).

(c) The bars shall include sufficient studs for the independent connection of each earth. The studs
shall be a minimum size of _ in (M 10).

(d) The lengths of the bars shall be such that at least 25% spare space complete with studs, nuts and
washers is included on each bar for future use.

(e) The interconnection of earth bars shall be by means of solderless connections (e.g. bolted lug type
connectors). The connectors shall be sized for the conductor diameter with only one conductor in
each connector.

3.4 Safety Earth System

3.4.1 Field Mounted Instruments, Junction Boxes and Local Control Panels

(a) All instruments, junction boxes and local control panels with metallic bodies shall have an
 GENERAL ENGINEERING SPECIFICATION GES J.17
EARTHING OF INSTRUMENT SYSTEMS Page 7 of 11
Rev 0 1999
external earth stud to allow connection of the body to a local earth.

(b) Where the instrument is supported on stands by "U" type clamps or socket mounting, the external
earth stud shall be connected to the plant earth via the mounting stand earth stud.

(c) The earth connections shall be made using 12 AWG (2.5 mm2) minimum cross section conductors.

(d) Where flange mounted instruments are used, earthing may be achieved by the use of serrated
spring washers on the fixing bolts. In hazardous areas, a separate earth connection shall be
provided from the internal/external earth stud to a local earth.

(e) Where glands are fitted to a tapped hole or where serrated washers are used in fitting glands to a
clearance hole in a metal box, additional earth connections between glands or between glands and
equipment are optional.

(f) Where non-metallic bodies are used, the earthing of internal metalwork shall be achieved via the
cable armouring or by connection to the gland plates. Gland plates shall be provided with earth
studs to link all gland plates to a local earth.

(g) Compression type cable glands shall be used to ensure a good electrical connection between the
gland and the cable armouring without degrading the ingress protection capability of the
enclosure.

(h) Metallic local control cabinet doors or hinged junction box covers shall be connected to the
cabinet or junction box by means of flexible (braided) earth straps.

3.4.2 Control Room Equipment

(a) The control room shall contain a main plant earth bar and one or more safety earth bars. The
control room safety earth bar(s) shall be directly connected to the plant earth bar. The connecting
earth cable shall be of sufficient cross section to allow electrical protective devices to operate
rapidly, and adequately sized not to be damaged by the fault. A 2 AWG (35 mm2) minimum cross
section conductor shall be used.

(b) Each cabinet containing electrical equipment, shall be fitted with a safety earth bar for connection
to the plant safety earth. The cabinet safety earth bar shall be electrically continuous with the
cabinet metal. All external metallic components shall be securely connected to the earth bar.

(c) All items of equipment within consoles and cabinets with a supply of more than 50 volts shall be
individually earthed to the cabinet safety earth bar.

(d) The armouring of cable entering control room mounted cabinets shall be stripped back to the cable
glands (where fitted) or to a point external to the cabinets. Where cable glands are not fitted, the
armouring shall be clamped. The gland grounding tags or armour clamps shall be connected to the
cabinet earth bar using a 12 AWG (2.5 mm2) cross section conductor. Cable armouring shall be
insulated from shielding throughout the cable run.

(e) Each cabinet earth bar shall be directly connected to the control room safety earth bar by dual
conductors.

(f) Each earth conductor shall be of sufficient cross section to allow the electrical distribution
protective devices to operate rapidly, and be adequately rated not to be damaged by the fault
current. As a guide, it may be taken that the safety earth cable minimum cross section may be
made in accordance with the following table.

Table 1. Safety Earth Cable CSA

 GENERAL ENGINEERING SPECIFICATION GES J.17
EARTHING OF INSTRUMENT SYSTEMS Page 8 of 11
Rev 0 1999
Cross Sectional Area of Supply Conductor (X) Cross Sectional Area of Earth Conductor
X < 5 AWG (16 mm2) Same size as supply conductor

5 AWG (16 mm2) < X < 2 AWG (35 mm2) 5 AWG (16 mm2)
X > 2 AWG (35 mm2) X/2

(g) The colour of safety earth connector sheathing shall be green/yellow.

(h) Cabinet and panel doors shall be positively connected to the cabinet by means of flexible (braided)
earth straps.

3.4.3 Cable Trays and Ladders

(a) All individual components of a cable ladder and tray within an area shall be interconnected by
means of propriety straps or by 10 AWG (6 mm2) earth conductors.

(b) The cable racks and trays shall be bonded to steelwork at approximately 80 ft (25 m) intervals and
at the ends of the runs.

3.5 Instrument Earth and IS Earth System

3.5.1 Instrument Cable Screens

(a) The cable screens of each instrument loop shall be electrically continuous and earthed at one point
only at the control room.

(b) The cable screens shall be insulated from all earths other than at the single connection point. For
non-IS loops, the earth connection shall be to the instrument earth and for IS loops to the IS earth.

(c) Field instruments, junction boxes and local control panels shall include terminal facilities for the
termination of cable screens. The termination points shall be isolated from the earth.

(d) Cables shall be made off and glanded so that there is no possibility of short circuits between the
screen/drain wire and the cable armour or gland body.

(e) Cable screens for non-earthed field instruments shall be connected to the cabinet instrument earth
bar in the control room.

(f) Where the instrument design requires the screen to be earthed at a local earth point, this shall be
done at the first junction box after the instrument. The screen shall be segregated and insulated
from other screen connections.
 GENERAL ENGINEERING SPECIFICATION GES J.17
EARTHING OF INSTRUMENT SYSTEMS Page 9 of 11
Rev 0 1999
3.5.2 Control Room Cabinets

(a) Each instrument field cable terminating cabinet shall be fitted with an instrument earth and if
required an IS earth bar for the connection of the cable screens and other instrument earth
connections. The earth bars shall be isolated from the cabinet metal by insulators with a minimum
spacing of 2 in (50mm) from the cabinet frame. The instrument earth and IS earth shall be
separate from and insulated from safety earth.

(b) The control room shall contain one or more instrument earth bars and IS earth bars if required.
The control room instrument earth bar(s) and IS bar(s) shall be directly connected to the main
plant earth bar using dual 2 AWG (35 mm2) conductors.

(c) Each cabinet instrument earth bar and IS bar shall be sized to allow for the individual connection
of each screen drain wire and other connections.

(d) Each cabinet instrument earth bar shall be individually and directly connected to a control room
instrument earth bar using dual 4 AWG (16 mm2) conductors. Cabinet IS earth bar shall be
connected similarly, to a control room IS earth bar.

(e) All spare cores of multicore cables shall be individually terminated on terminals. The terminals
shall be linked, with one terminal being connected to the cabinet instrument earth bar or IS bar
depending on the type of cable (non-IS or IS cable).

(f) The "shield" connection of amplifiers, etc., shall be connected to the cabinet instrument earth bar.

(g) The 0 volt line of non-isolated instrument power supplies shall be connected to the cabinet
instrument earth bar.

(h) The colour of instrument earth connector sheathing shall be green.

(i) Each end of the cable shall be clearly labelled with the function of the cable.

(j) The earthing of screens, signal wiring and 24 volt power supplies for the following
instrumentation systems shall take into consideration the manufacturer's recommendations for
earthing such systems and shall be approved by the Owner:

- process control/display systems;

- fiscal flow metering systems;

- gas detection systems;

- telemetery panels;

- computer systems;

- grounded thermocouple systems.

3.5.2 Intrinsically Safe Barrier Systems

(a) IS loops shall be segregated from other loops, run in independent cables, and preferably through
dedicated junction boxes.
 GENERAL ENGINEERING SPECIFICATION GES J.17
EARTHING OF INSTRUMENT SYSTEMS Page 10 of 11
Rev 0 1999
(b) Zener barrier installations normally include a barrier earth bar per set of barriers. The barrier earth
bars shall be directly connected to the cabinet IS earth bar using a minimum of dual
12 AWG ( 4 mm2) conductors.

(c) The use of floating power supplies with barrier systems shall be avoided due to the occurance, of
possible earth faults. The preferred system shall be two channel barriers with an earthed 24 volt
supply. The earth point of the 24 volt supply shall be the IS earth bar.

(d) Galvanically isolated barrier sets need not include a barrier earth bar. The cable screens and spare
cores of cables connected to galvanically isolated barriers shall be earthed to the IS cabinet earth
bar.

(e) The impedance between the barrier earth bar and the plant earth shall be less than one ohm,
measured for each leg of the dual circuit.

(f) The colour of IS earth connector sheathing shall be green with blue bands at each end and at
intermediate locations.

(g) Electrical contact between the thermocouple element and pocket or head assembly shall be
prevented by the use of insulating element sheath. When subjected to a test voltage of 500 volts,
the complete thermocouple assembly shall have a greater 10k Ohms resistance. The use of
grounded tip thermocouple shall require the Owner's approval.

4.0 INSTALLATION

(a) Screen drain wires of non-IS cables shall be fitted with insulating green heat shrink sleeves. For IS
cables the greeen heat shrink sleeves shall have blue bands.

(b) IS earth conductors shall have additional blue bands permanently placed at each cable marker.

(c) Uninsulated wires, e.g. screen drain wires shall be covered by yellow/green striped sleeves. These
shall be blue banded for IS services.

(d) IS earth bars shall be marked with blue paint or tape at each end of the bar.

(e) Instrument and IS earth bars shall be fitted with protective plastic covers to prevent unauthorised
connections.

(f) All terminations shall be thoroughly cleaned and free from paint, grease, dirt, etc., before making
the earth connection. Terminations on steelwork shall be sealed with copper grease.

(g) All ground fittings, i.e. studs, nuts, washers, etc., shall be made from brass.

(h) Each earth bar shall be identified by a label made from laminated plastic. The character shall have
a minimum height of ½ in (12 mm) minimum and shall be BLACK characters on white
background for the safety and instrument earth bars, and BLUE characters on white background
for IS earth bars.

(i) The labels shall have the following engraving:

- SAFETY EARTH

NO UNAUTHORISED CONNECTIONS OR DISCONNECTIONS

- INSTRUMENT EARTH
 GENERAL ENGINEERING SPECIFICATION GES J.17
EARTHING OF INSTRUMENT SYSTEMS Page 11 of 11
Rev 0 1999
NO UNAUTHORISED CONNECTIONS OR DISCONNECTIONS

- INTRINSICALLY SAFE EARTH

NO UNAUTHORISED CONNECTIONS OR DISCONNECTIONS

(j) Earthing cables shall be installed so that they remain accessible without removing cables for other
services.

(k) Earth bars shall be installed such that there is ample space around them with adequate access for
testing purposes.

(l) Direct contact of dissimilar metals should be avoided as far as possible. Where contact is
unavoidable suitable proprietary compounds shall be used to prevent electrolytic action and at the
same time allow conduction. The compound shall be silicone free.

5.0 TESTING AND INSPECTION

(a) The control room earth systems shall be tested before the connection of external components, e.g.
cable screens, barrier bars and instrument shields.

(b) All connections shall be visually and mechanically checked for tightness, shrouding and
identification.

(c) All systems shall be tested for continuity from the cabinet earth to the plant earth. Measurements
shall be taken for each leg in the dual system. The loop impedance of each leg shall be better than
1 ohm.

(d) The instrument and IS earth shall be disconnected from the plant earth and the isolation of the
systems from the plant earth shall be checked. This shall be carried out using a tester operating at
500 V (double check that barriers, etc., have been disconnected).

(e) A visual check shall be carried out on the earth and screen connections on all field instruments,
junction boxes and local panels. Continuity measuring instruments suitable for use in hazardous
areas shall be used.

(f) When all checks are complete, the screens, barrier bars and instruments shall be connected.

(g) Earth continuity of cable tray and ladder sections shall be tested.

(h) The Owner shall witness tests on the IS system's earthing in accordance with the procedures
detailed in BS 5345 Part 4, concerning insulation and continuity.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES J.24

FIRE AND GAS INSTRUMENTATION

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES J.24
FIRE AND GAS INSTRUMENTATION Page 2 of 31
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 45

2.1 Technical 45
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 System Requirements 7
3.3 Fire & Gas Detection 8
3.4 Manual Alarm Call Points 8
3.5 Plant Linear Heat Detectors (Fusible Plastic Tube) 9
3.6 Plant Linear Heat Detectors (Heat Sensitive Cable) 9
3.7 Infra-Red and Ultra-Violet Detectors 9
3.8 Point Smoke Detectors 10
3.9 Point Heat Detectors 10
3.10 Air Sampling Type Smoke Detectors (VESDA) 11
3.11 Beam Smoke Detectors 11
3.12 Flammable Gas Detectors 11
3.13 Toxic Gas Detectors 12
3.14 Central Fire and Gas Control Panel 13
3.15 Input/Output Modules 14
3.16 System Interfacing 15
3.17 Applications Software 15
3.18 Power supply 15
3.19 Cabinets 16
3.20 Wiring and Terminations 16
3.21 Cabling 16
3.22 Earthing 16
3.23 Operator Displays 16
3.24 Plant Audible and Visual Alarms 17
3.25 Fire Water Pump Control 17
3.26 Building Inert Gas Protection 18

4.0 MATERIALS 18

5.0 MANUFACTURE 18

5.1 Identification and Labelling 18

 GENERAL ENGINEERING SPECIFICATION GES J.24
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SEC TITLE PAGE

6.0 INSTALLATION 19

6.1 Manual Alarm Call Points 19

6.2 Plant Linear Heat Detectors (Fusible Plastic Tube) 19
6.3 Plant Linear Heat Detectors (Heat Sensitive Cable) 20
6.4 Infra-Red and Ultra-Violet Flame Detectors 20
6.5 Point Smoke Detectors 20
6.6 Point Heat Detectors 20
6.7 Air Sampling Type Smoke Detectors (VESDA) 21
6.8 Beam Smoke Detectors 21
6.9 Flammable and Toxic Gas Detectors 21

7.0 INSPECTION 22

7.1 Visual Inspection 22

8.0 TESTING 22

8.1 Heat Soak Test 22

8.2 Factory Acceptance Testing 23
8.3 Field Device Testing and Commissioning 24

9.0 DOCUMENTATION 24

9.1 Introduction 24
9.2 Schedules and Reports 25
9.3 Data and Calculations 25
9.4 Drawings 25
9.5 Final Records, Documents and Manuals 25
9.7 Certificates 25

10.0 PRIOR TO SHIPMENT 25

10.1 Painting and Coatings 25

10.2 Spares 26
10.3 Packing and Storage 26
10.4 Shipping 26
10.5 Warranty 27

FIGURES

Figure 1 Linear Heat Detectors (Plastic Tube) 28

Figure 2 Standard Sensor Nomogram 29
Figure 3 Centre Line Range Against Petrol Flames 30
Figure 4 Relative Range as Function of Angle of Incidence 30
Figure 5 Central Fire and Gas Monitoring Unit 31
 GENERAL ENGINEERING SPECIFICATION GES J.24
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the design, manufacture, selection,
installation, inspection and testing of fire and gas instrumentation systems.

1.1.2 This specification applies to fire and gas equipment for refineries, onshore oil and gas installations
and processing facilities including items purchased either directly or as part of a package.

1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.4 In the event of any conflict between this specification and the data sheets, or with any of the
applicable codes and standards, the Vendor/Contractor shall inform the Owner in writing and
receive written clarification before proceeding with the work.

1.1.5 This General Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

The following NOC Specifications are an integral part of this specification and any exceptions
shall be approved in advance by the Owner.

GES H.01 Fire and Gas Alarm Systems

GES H.06 Fixed Water Spray Systems

GES H.07 Fire-Fighting Facilities for Storage Tanks

GES H.08 CO2 and Halon Substitute Systems

GES J.12 Indoor Control Panels and Cabinets

GES J.15 Instrument Air Systems

GES J.16 Instrument Cable and Cabling

GES J.17 Earthing of Instrument Systems

GES J.21 Programmable Logic Controllers

GES L.31 Area Classification

GES L.35 Electrical Equipment in Hazardous Areas

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

 GENERAL ENGINEERING SPECIFICATION GES J.24
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LEL (Lower Explosive Limit)

The concentration of flammable gas, vapour or mist in air, below which an explosive gas
atmosphere will not be formed.

Manual Alarm Call Points

A device for manually initiating a fire alarm. Normally consists of a spring actuated switch
retained by a glass plate. The switch is released when the glass plate is broken.

Heat Detectors

Devices which are sensitive to temperature or rate of temperature increase caused by a fire.

Smoke Detectors

Devices which are sensitive to the presence of the smoke particles generated by overheated or
burning materials.

Flame Detectors

Devices which are sensitive to infra-red, ultra-violet and/ or visible radiation emitted by burning
materials.

Heat Sensitive Cable

A heat sensitive cable consists of a number of copper conductors, each covered with a negative
temperature coefficient material, and twisted together within a flame retardant outer sheath.
A change in temperature produces a change in the resistance between any two cores which can be
monitored by an associated electronic interface unit.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and
facilities.

Vendor

The company supply the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a contractor to do part of the work awarded to the Contractor.
 GENERAL ENGINEERING SPECIFICATION GES J.24
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Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment
and facilities have been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verified that the equipment and facilities have been designed, constructed,
inspected and tested in accordance with the requirements of this specification and the Purchase
Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

API 2001 Fire Protection in Refineries.

BS 4683 Specification for Electrical Apparatus for Explosive Atmosphere

Classification for Maximum Surface Temperatures

BS 5839: Part 1 Code of Practice for System Design, Installation and Servicing
in Hazardous Areas

Part 2 Fire Detection and Alarm Systems in Buildings - Specification

for Manual Call Points

BS EN 54 Part 1 Components of Automatic Fire Detection Systems-

Introduction.

Part 5 Components of Automatic Fire Detection Systems - Heat

Sensitive Detectors-Point Detectors Containing a Static
Element

Part 6 Components of Automatic Fire Detection Systems- Heat

Sensitive Detector - Rate of Rise Point Detectors Without a
Static Element.

Part 7 Components of Automatic Fire Detection Systems- Point

Type Smoke Detectors - Detectors Using Scattered Light,
Transmitted Light or Ionisation.

Part 8 Components of Automatic Fire Detection Systems- High

Temperature Heat Detectors.

Part 9 Components of Automatic Fire Detection Systems - Fire

Sensitivity Test. BS 6020 Instruments for the Detection of
Combustible Gases

BS 6959 Code of Practice for Selection, Use and Maintenance of Apparatus for
the Detection and Measurement of Combustible Gases
 GENERAL ENGINEERING SPECIFICATION GES J.24
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BS EN 50054 Electrical Apparatus for the Detection and Measurement of
Combustible Gases - General Requirements and Test Methods

BS EN 50057 Electrical Apparatus for the Detection and Measurement of

Combustible Gases - Performance Requirements for Group II
Apparatus Indicating up to 100% Lower Explosive Limit

BS EN 50058 Electrical Apparatus for the Detection and Measurement of

Combustible Gases - Performance Requirements for Group II
Apparatus Indicating up to 100% (V/V) Gas

IEC 60605: Part 1 Equipment Reliability Testing - General Requirements

IEC 61000: Part 4.2 Electromagnetic Compatibility (EMC) - Testing and

Measuring Techniques Electrostatic Discharge Immunity Test

IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)

ISA RP 12.13 Part 2 Installation, Operation, and Maintenance of Combustible Gas

Detection Instruments

ISA RP 92.0.02 Installation, Operation, and Maintenance of Toxic Gas

Detection Instruments: Hydrogen Sulphide Detectors

NFPA 20 Installation of Centrifugal Fire Pump and Fire Pump

Handbook Set

NFPA 72 National Fire Alarm Code

NFPA 80 Fire Doors and Fire Windows

NFPA 90A Installation of Air Conditioning and Ventilating Systems

3.2 System Requirements

3.2.1 Fire and Gas instrumentation and systems shall be designed to provide, as defined in the project
specification, the following main functions:

- Detection of a fire in its early stages.

- Detection of the presence of flammable and/or toxic gases.

- Alarm indication and reporting, both visual and audible.

- Fault indication.

- Implementation of all logic and voting requirements.

- Automatic initiation of protective systems.

- Communication/interfacing with other systems or equipment such as Fire & Gas

equipment, Emergency Shutdown Systems, Distributed Control Systems (DCS), SCADA
Systems and HVAC equipment.
 GENERAL ENGINEERING SPECIFICATION GES J.24
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Rev 0 1999
3.2.2 The system shall include an integrated Fire & Gas Control and Indicating Panel together with
associated power supplies, field detectors, alarm indicating devices, and all system interconnecting
cables.

3.2.3 The Fire & Gas Control and Indicating Panel shall preferably be based on programmable digital
technology.

3.2.4 Addressable detectors and alarm indicators (beacons and sirens) shall be used wherever possible.
Addressable detectors and alarm indicators may be connected in radial or loop configurations.

3.2.5 It shall be possible to incorporate existing systems, using switch type detectors and existing
cabling, in the Fire & Gas system.

3.3 Fire & Gas Detection

3.3.1 Fire detection signals shall be either manually or automatically initiated. Manual initiation shall
be via manual call points or break glass units. Automatic initiation shall either via heat, smoke
and/or flame detectors.

3.3.2 Gas detectors may be either for the detection of flammable gas or toxic gas. In both cases fixed
installations only shall be considered.

3.3.3 All field located equipment shall be have ingress protection to IP 65 in accordance with IEC
60529. Those installed in hazardous areas shall be certified intrinsically safe by an internationally
recognised certifying authority. In general they shall carry approval for installation in Zone 1
Hazardous Area, Apparatus Gas Group IIA and IIB, Temperature Classification T6 unless advised
to the contrary. Equipment certified to CENELEC standards are acceptable. Where specified, the
requirements shall be in accordance with the "Area Classification Drawings".

3.4 Manual Alarm Call Points

3.4.1 Manual alarm call points shall be specified either for outdoor mounting in the plant or for
mounting in buildings.

3.4.2 Manual call points shall either be of the break glass auto-release type, or the break glass manual
switch operation type. The units shall be provided with single pole, double throw, hermetically
sealed switches. The contacts shall normally be open when the glass is unbroken.

3.4.3 The housing material for "indoor" manual call points shall be to the Vendor/Contractor's standard
with a minimum ingress protection to IP 54 in accordance with IEC 60529 for both switch housing
and button/glass chamber. The glass shall be splinter-proof to the Vendor/Contractor's standard or
have plastic coating.

3.4.4 The housing shall contain all components necessary for line monitoring, i.e. end of line resistors
(non-addressable systems).

3.4.5 Each manual alarm call point shall be provided with a hammer, attached to the housing by a
chain. Keys shall be provided for dismantling and testing.

3.4.6 Each housing shall be coloured red, and shall have the word FIRE engraved in Arabic and English
on the glass retaining plate.

3.4.7 The housings shall have ¾ in NPT cable entries at the top and bottom fitted with approved plugs.

3.4.8 The manual alarm call points shall be looped on two core circuits. Where the detectors are not
addressable, no more than nine detectors shall be connected to one circuit.

3.5 Plant Linear Heat Detectors (Fusible Plastic Tubing)

 GENERAL ENGINEERING SPECIFICATION GES J.24
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Rev 0 1999

3.5.1 Linear heat detectors shall be used in plant areas where other methods may not give the required
discrimination. Typical examples are pump seals and vessels.

3.5.2 Linear heat detectors based on fusible plastic tubing shall be used for the detection of fire on plant
equipment where instrument air is available.

3.5.3 Linear heat detectors shall be assembled from polyethylene tubing and pressurised with instrument
air via a restriction orifice. In the event of a fire, the plastic tubing will melt at approximately
175°F (90°C) and the drop in air pressure detected by a pressure switch (Figure 1). Tubing which
may self-seal after softening shall not be used.

3.5.4 The time of operation of the pressure switch shall be less than 30 seconds after the fusing of the
tubing.

3.5.5 Where automatic fire-fighting is initiated by the heat detector, the use of two identical systems
with 2-out-of-2 voting shall generally be implemented. An alarm only shall be raised if one
system operates.

3.5.6 Linear heat detectors shall be individually connected, i.e. shall not be looped with other detectors.

3.6 Plant Linear Heat Detectors (Heat Sensitive Cable)

3.6.1 Linear heat detectors based on "analogue" heat sensitive cables shall be used for the detection of
fire on plant equipment where instrument air is not available.

3.6.2 The maximum alarm temperature shall be calculated by reference to the manufacturer's nomogram
relating ambient temperature, interface unit sensitivity and cable length. For typical nomogram
see Figure 2.

3.6.3 Where automatic fire-fighting is initiated by the heat detector, the use of two identical systems
with 2-out-of-2 voting shall be implemented. An alarm only shall be raised if one system
operates. The dual system may be implemented by four cores in the one cable.

3.6.4 Heat sensitive cables may be used with suitable safety barriers and located in hazardous areas
being regarded by certifying authorities as simple electrical apparatus. The sensor interface unit
shall be located in a safe area.

3.6.5 Linear heat detectors shall be individually connected, i.e. shall not be looped with other detectors.

3.7 Infra-red and Ultra-violet Flame Detectors

3.7.1 Flame detectors shall be either infra-red or ultra violet or a combination of the two. They shall be
used for the fast detection of fires in a general open plant area.

3.7.2 IR detectors by detecting the radiation in the infra-red spectrum of about 4.4 micrometres (C02
band) given off by hydrocarbon fires shall be used. Alternatively, UV detectors detecting the
radiation in the ultra-violet spectrum typically between 180 and 250 nanometres shall be used.
Since UV detectors are sensitive to welding activities, X and gamma rays, direct sunlight and
lightning, combination UV/IR detectors are preferred.

3.7.3 Flame detectors shall be located to comprehensively cover a particular area. They shall be
positioned to avoid the detection of flame from an adjacent area.
 GENERAL ENGINEERING SPECIFICATION GES J.24
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3.7.4 All flame detectors shall have solar blind and their response to other sources of radiation
minimised.

3.8 Point Smoke Detector

3.8.1 Point smoke detectors shall be used for the protection of indoor areas. The smoke detectors shall
be either of the "ionisation" or "optical" type.

3.8.2 Addressable detectors shall, when interrogated by the Fire & Control Panel, transmit smoke level
readings.

3.8.3 All point detectors shall be installed in a twist lock base supplied with the detector. The detector
base shall be suitable for surface mounting.

3.8.4 Ionisation type smoke detectors shall be used to detect small particles (below 1 micrometres),
produced by flaming fire. They are less sensitive to larger particles and therefore should be
installed together with optical detectors for the detection of smouldering fires.

3.8.5 Optical smoke detectors shall be of the "pulsed light source" type.

3.8.6 Optical smoke detectors shall be used to detect visible particles given off by smouldering fires
(between 1 and 100 micrometres) and lighter coloured (reflecting) smoke than black (absorbing)
smoke.

3.8.7 The detection of a range of smoke particle size shall be achieved by interspacing ionisation and
optical detectors.

3.8.8 Optical smoke detectors may be used in place of ionisation smoke detectors where the use of
ionisation detectors is prohibited because of the small amount of radioactive material present.

3.8.9 The location and spacing of smoke detectors shall be in accordance with NFPA 72.

3.8.10 Point smoke detectors shall have an integral red LED smoke alarm indication and shall be have
facilities for driving remote LED displays for alarm indication where the detector is not visible
(e.g. in a ceiling space).

3.8.11 An open circuit fault condition shall be initiated if a detector is removed from its base.

3.8.12 Detectors of the same type shall be interchangeable.

3.8.13 The detectors shall be looped on two core circuits. Where the detectors are not addressable, no
more than nine detectors shall be connected to one circuit (Zone).

3.9 Point Heat Detectors

3.9.1 Heat detectors shall be used in enclosed areas where smoke detectors are unsuitable e.g. kitchens.

3.9.2 Point heat detectors shall incorporate both rate-of-rise and fixed temperature operating elements.
The detectors shall include thermistor network in its circuitry.

3.9.3 Addressable detectors shall, when interrogated by the control panel, transmit ambient temperature
and alarm condition readings.

3.9.4 All point detectors shall be installed in a twist lock base supplied with the detector. The detector
base shall be suitable for surface mounting.

3.9.5 The operating temperature of sensors shall not be more than 54°F (30°C) above the normal
ambient temperature.
 GENERAL ENGINEERING SPECIFICATION GES J.24
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3.9.6 The fixed element shall have an accuracy of ± 5% of the setpoint temperature.

3.9.7 Heat detectors shall have an integral red LED alarm indication and shall have facilities for driving
remote LED displays for alarm indication where the detector is not visible.

3.9.8 The location and spacing of heat detectors shall be in accordance with NFPA 72.

3.9.9 The detectors shall be looped on two core circuits. Where the detectors are not addressable, no
more than nine detectors shall be connected to one circuit (Zone).

3.10 Air Sampling Type Smoke Detectors (VESDA)

3.10.1 Air sampling systems, which continuously monitor for smoke in air drawn from protected areas
are available under the generic name of VESDA (Very Early Smoke Detection Apparatus) shall be
used.

3.10.2 Air sampling systems shall be installed in mechanically ventilated areas where cables are installed,
e.g. under control room floors and above ceilings. They may also be used in equipment cabinets.

3.10.3 Air sampling systems shall include an alarm to indicate when the sampling flow rate is outside the
Vendor/Contractor recommended range.

3.10.4 The control unit detector shall be of the light scattering indicating type.

3.10.5 The sampling tubing shall be to the Vendor/Contractor's standard, but shall not normally be
greater than 1 in (25mm) plastic.

3.10.6 Details of the mechanical ventilation system shall be given to the Vendor/Contractor who shall
design the sampling network including the location of the sample tubing and the location and size
of the pipe perforations. The Vendor/Contractor shall provide calculations showing flow
characteristics for the network and each sampling point.

3.11 Beam Smoke Detectors

3.11.1 Beam smoke detectors shall be used in large open-type interiors such as warehouses workshops
and pump houses or in cable ducts where the installation and maintenance of point-type detectors
may be difficult or impractical.

3.11.2 The receiver shall include automatic gain control to compensate for the long term degradation of
signal strength caused by component ageing and the build of dirt on optical surfaces.

3.11.3 In the event of power failure or where the beam is severely attenuated below the maximum
practicable smoke attenuation level (e.g. by a solid object), a fault alarm shall be given. The fault
alarm shall inhibit the smoke alarm.

3.12 Flammable Gas Detectors

3.12.1 Point Flammable gas detectors shall be of the catalytic combustion type. Only detectors resistant
to H2S poisoning shall be specified. The detectors shall be complete with high performance
sensors, stainless steel housing, flame arrestor and protective filter. The sensor element shall be
exchangeable without changing the housing. Outdoor detectors shall be weatherproof.

3.12.2 The detectors shall give a 4-20 mA output and include the local indication of current to allow for
"one man" calibration.

3.12.3 Flammable gas detectors shall be installed in locations where a gas leak is likely to occur and give
 GENERAL ENGINEERING SPECIFICATION GES J.24
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rise to hazardous atmospheres. They shall also be installed in places such as:

- instrument air compressor intakes;

- sampling/maintenance points and analysers enclosures;
- HVAC air intakes in buildings.

3.12.3 Sources of ignition shall be identified on a plot plan in correlation with the possible sources of
release, prevailing wind direction and location of gas detectors.

3.12.4 The detector shall respond to flammable gas concentrations over the range 0 to 100% LEL. The
detector output shall maintain its value when the saturation point of the detector is exceeded.

3.12.5 Each detector shall be fitted with a filter. Filters shall be used to complete the seal where
collecting cones and other accessories such as weather protection housings are used.

3.12.6 The detector receiver shall generate an alarm at 25% LEL, and initiate shutdown action at 50%
LEL.

3.12.7 The action following an alarm shall be determined by the Owner. In general, manual shutdown
action shall be carried out by the operator following acceptance of an alarm. In critical cases
automatic shutdown action shall be based on at least 2-out-of-3 voting on the results of the outputs
of at least three grouped detectors (e.g. on air compressor intakes).

3.12.8 The detector response shall be calibrated for the combustible levels of combustible gases such as
methane, hydrogen, ammonia and methanol.

3.12.9 Infra-red detectors may be considered where "line of sight" (open path) monitoring is possible, i.e.
perimeter monitoring.

3.12.10 Because infra-red detectors integrate the absorption and hence the gas concentration over the
length of the beam, the alarm levels shall be set in units of LEL feet. One LEL foot is the path
integrated absorption caused by an amount of hydrocarbon gas equivalent to 100% LEL methane
over one foot of the path.

3.12.11 The infra-red detector shall include an alarm which, after a preset time, shall give an indication of
beam blocking. The preset time shall be sufficient to allow for the short term transit of people and
vehicles, i.e. approximately 10 seconds.

3.13 Toxic Gas Detectors

3.13.1 Point toxic gas detectors for a the detection of hydrogen sulphide (H2S) for personnel protection
shall be of the electrochemical type.

3.13.2 Toxic gas detectors are suitable for a specific gas and individual detectors shall be specified for
other toxic gases, e.g. carbon monoxide, hydrogen chloride, ammonia, methanol and chlorine gas.

3.13.3 Each detector shall be fitted with a hydrophobic barrier. Filters shall be used to complete the seal
where collecting cones and other accessories such as weather protection housings are used.
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3.13.4 The range of the detectors shall be 0-50 ppm of H2S. with alarms initiated at 6 and 15 ppm; 0-
100ppm for ammonia with alarms at 15ppm and 40ppm; and 0-1,000 ppm for methanol with
alarms at 120 and 300 ppm.

3.13.5 The detectors shall give a 4-20 mA output and include the local indication of current to allow for
"single man" calibration.

3.14 Central Fire and Gas Control Panel

3.14.1 The control Fire and Gas control panel shall be an "intelligent" system capable of supporting
conventional and addressable devices. It shall be fault tolerant, incorporate extensive fault
diagnostics and be based on the "Open System" philosophy (e.g. Modbus) with respect to
communication with other systems.

3.14.2 The control Fire and Gas control panel shall be capable of:

- continuously monitoring the fire & gas detection system for a signal indicating a fire or
gas, and identifying its location;
- carry out 2-out-of-N voting where executive action (eg plant shutdown and/or
depressuring) is required following a fire or gas alarm;
- starting and monitoring the running of fire water pump(s);
- initiating the operation of an automatic fire protection system, e.g. the release of a water
spray or CO2 system;
- interfacing with the plant ESD system to initiate equipment, production/utilities shutdown
(where required);
- initiating building ventilation fan and inlet damper shutdown (where required);
- initiating audible and visual fire alarms in the plant, in control rooms and fire stations;
- monitoring for device and cable faults on all detectors, alarm devices and cables;
- continuously monitoring the fire and gas detectors for incipient faults;
- continuously presenting information to the Operator's interfaces, e.g. alarm panels, mimic
panels, and communicating with other systems e.g. Distributed Control Systems (DCS) or
SCADA systems.

3.14.3 The preferred system shall be microprocessor based. Where the system is small, discrete solid
state modules may be used.

3.14.4 Addressable systems shall be capable of indicating point and circuit alarms. Addressable systems
shall be capable of being connected either radially or on a ring basis.

3.14.5 The central Fire and Gas control panel shall have an availability in excess of 99.95% (based on a
4-hour mean time to repair). Where this availability cannot be achieved by a single unit,
redundant technology shall be used. Dual redundancy or TMR (triple modular redundancy)
systems operating on a 2-out-of-3 voting may be used.

3.14.6 Reliability test specifications shall be prepared by the Vendor/Contractor in accordance with the
requirements of Section 13 of IEC 605-1.

3.14.7 Where multiple processing units are used, the same data base shall be used by all processors. Any
data base changes shall be effected in all units to ensure uniform data bases throughout the system.

3.14.8 The system shall carry out self-diagnostic checks on all processing units.

3.14.9 The system shall monitor all power supplies and report any failures.

3.14.10 It shall be possible to override detector inputs at the system console for the purpose of
maintenance.
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3.14.11 Access to the system to set overrides and alter alarm settings shall be under key control.

3.14.12 The system shall include a facility for the logging, storage and retrieval of all alarms and input
overrides. The storage capacity shall allow for a minimum of 24 hours of historical data and shall
be organised on a first in first out basis.

3.14.13 Alarms and overrides shall be reported in chronological order and shall include time and date
information. The Vendor/Contractor shall specify the resolution of the system.

3.14.14 It shall be possible to display current and retrieved information by command from the system
keyboard.

3.14.15 It shall be possible to acknowledge and reset alarms by command from the system keyboard.

3.14.16 It shall be possible to initiate output sequences and printouts by command from the system
keyboard.

3.14.17 The system shall include a printer to log all alarms and overrides on occurrence and on demand.

3.14.18 A system configuration console/PC shall be provided for the purpose of carrying out approved
logic and other system changes.

3.14.19 The design of the fire and gas system shall be such that it is not affected by electromagnetic
interference as defined in IEC 801-3. The frequencies generated by hand-held radio transceivers
are considered to be the dominant source.

3.15 Input/Output Modules

3.15.1 The central Fire and Gas control panel shall include input/output modules for the interfacing of
detectors to the logic units. The modules shall normally plug in to the main control panel. The I/O
modules shall also process the data from the detectors and indicate the status conditions.

3.15.2 All input/output modules shall include self test diagnostics to detect and indicate module failure.

3.15.3 Where 2 out of 2 ( or 2 out of 3) voting is carried out on inputs, the inputs shall be connected to
separate I/O modules.

3.15.4 Input/output modules shall carry out the following functions:

- open loop detection;

- short circuit detection;
- earth fault detection;
- I/O power failure detection.
- Isolation of field devices.

3.15.5 Analogue inputs from gas detectors shall normally be 4-20 mA. Fault alarms shall be generated
where the input rises above 20 mA or falls below 4 mA. Digitally coded signals may be accepted
from addressable devices. The digital display of each gas detector shall be provided at the input
module.
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3.15.6 Digital outputs, with the exception of lamp drivers for mimic panels and local panels, shall be of
the potential free contact closure type. The output contact shall be suitably rated for the output
device.

3.15.7 Power digital outputs for lamps, etc shall be protected against short circuit.

3.15.8 The failure of any module or input/output channel shall initiate an alarm.

3.15.9 The safety barriers for intrinsically safe loops shall be mounted within the I/O system.
Intrinsically safe systems shall be segregated from all other inputs and outputs after the barriers.

3.16 System Interfacing

3.16.1 Figure 5 shows a typical interfacing arrangement.

3.16.2 The central Fire and Gas control panel shall include the facilities necessary for interfacing to other
systems.

3.16.3 Parallel interfaces shall be used where an executive action follows the transfer data. Potential free
contacts shall be used where positive isolation is required.

3.16.4 Communication with other DCS or SCADA systems for logging and reporting shall be by serial
interface using an industry standard protocol (e.g. MODBUS RTU).

3.16.5 A Centronix parallel interface shall be provided for a system printer.

3.17 Applications Software

3.17.1 Cause and effect charts shall be used as the basis for developing the application software. The
cause and effect charts shall be supplemented by functional logic diagrams where required.

3.17.2 The application software shall be represented in a readily understood, standard format (e.g. ladder
or functional logic). The software listing shall be adequately commented so that the functional
significance of each step can easily be established.

3.17.3 The Vendor/Contractor shall devise tests to confirm and demonstrate the correct operation of the
applications software.

3.17.4 The central Fire and Gas control panel shall include automatic self-check software routines to test
the systems capability to function as required on demand. The self-check software shall test all
critical I/O operations in addition to logic functions. Self-checking shall be carried out
automatically on system start-up and after any interruption in operation, e.g. power failure.

3.18 Power Supply

3.18.1 The system power supplies shall comply with the requirements of GES J.12.

3.18.2 Independent power supplies shall be provided for each redundant unit.

3.18.3 The power supplies shall include battery back-up to provide continuous operation at full load for
24 hours after mains input failure. Full load shall be defined as the total system power
requirements with all detectors in the alarm condition plus an allowance of 20% for future
expansion.

3.18.4 Low battery voltage and ground fault detection and alarms shall be provided.

3.18.5 The Vendor/Contractor shall supply calculations in support of the power supply and battery sizing.
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3.19 Cabinets

The system cabinets shall comply with the requirements of GES J.12.

3.20 Wiring and Terminations

The system wiring and termination shall comply with the requirements of GES J.12 and GES J.16.

3.21 Cabling

3.21.1 The system cabling shall comply with the requirements of GES J.16.

3.21.2 System cabling for the interconnection of system components, i.e. operator display, printers, etc
shall be supplied by the Vendor/Contractor.

3.21.3 Where specified in the Purchase Order/Contract the Vendor/Contractor shall supply field cabling
which shall be in accordance with the requirements of GES J.16.

3.22 Earthing

The earthing system shall comply with the requirements of GES J.17.

3.23 Operator Displays

3.23.1 The normal means of operator display, where a microprocessor system is used, shall be by console
mounted VDUs or LCD displays.

3.23.2 The VDUs or LCD displays shall provide the operator with clear and concise information relating
to fire and gas detection and the consequent control actions. Prompts shall be provided, where
required, to guide the operator through any sequence or procedure. Hydrocarbon gas and H2S
alarms shall be indicated by different colours.

3.23.3 The use of colours and symbols in all displays shall be consistent. The colour for fire alarms shall
be red, for hydrocarbon alarms shall be green and for H2S gas alarms shall be blue.

3.23.4 If a DCS or SCADA system is not used for operator display, then a mimic panel shall be placed in
the central control room and fire station.

The mimic panel shall be in the form of a simplified plot plan with lines of major equipment,
buildings and rooms within each building. Each fire area and fire zone within each fire area shall
be shown on the mimic. Fire and/or Gas detected within a fire area or fire zone shall be indicated
with an LED.

Detection of Fire shall be indicated by a red LED, flammable gas detection by a green LED and
toxic gas detection by a blue LED. The mimic panel shall also indicate any fault by fire zone. A
zone fault shall be indicated using yellow/amber LED.

The mimic panels and any local fire and gas indicating panels shall be under the control of central
Fire and Gas control panel.

3.23.5 Local fire and gas indicating panels shall be placed at the entrance to all unmanned buildings
where fire and gas detection or protection systems are installed.

The local panels shall give point indication of fire and gas detection and if the release of
quenching gases, e.g. CO2 has occurred. The fire and gas detectors may be identified by tag
number if insufficient panel space is available for the detector position to be indicated.
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3.23.6 All panels shall include alarm accept, reset and lamp test facilities.

3.24 Plant Audible and Visual Alarms

3.24.1 The central Fire and Gas control panel shall automatically initiate plant fire and gas audible and
visual alarms.

3.24.2 Each audible alarm shall be under time control. The timing shall commence at the alarm initiation
and shall be adjustable within the range to 10 minutes.

3.24.3 It shall be possible to manually initiate and cancel all plant audible and visual alarms from the
operator's console.

3.24.4 The sound level at one metre (3 ft) from the audible alarm shall be 104 dB or 5dB above ambient
noise.

3.24.5 Audible and visual alarms installed in open areas shall be weatherproof to IP 56 as defined in IEC
60529.

3.24.6 Flash (strobe) lamps shall be placed outside buildings where fire and gas detection systems are
installed to indicate a hazard inside the building. Also in high noise areas to supplement audible
alarms.

3.24.7 The visual alarms shall have a flash rate of 1 pulse per second.

3.24.8 The colour shall normally be amber, but other colours may be selected in accordance with local
requirements.

3.25 Fire Water Pumps Control

3.25.1 Unless otherwise stated by the Owner the fire water pump control system shall be in accordance
with NFPA 20.

3.25.2 The central Fire and Gas control panel shall start the main fire water pump on the confirmed
receipt of a fire alarm.

3.25.3 Where the fire water main pressure is maintained by a jockey pump or by the hydrostatic head of
the fire water storage tank, then the main fire water pump shall be started when the water main
pressure falls below a preset value, giving automatic starting of the fire water pump when a
hydrant is opened.

3.25.4 The central Fire and Gas control panel shall monitor the fire water mains pressure at all times. If
the fire water main does not attain the required pressure within approximately 20 seconds, then the
standby pump shall be automatically started by the system.
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3.25.5 The central Fire and Gas control panel shall monitor the fire water pump suction pressure at all
times to avoid the possibility of attempting to start and run a pump with insufficient suction
pressure. An alarm shall be raised to indicate this condition.

3.25.6 Where applicable the central Fire and Gas control panel shall be used to monitor and indicate the
level of the fire water storage tank.

3.26 Building Inert Gas Protection

3.26.1 Automatic inert gas protection (CO2 or Halon substitute) may be used in buildings and other
enclosed spaces which are normally unmanned.

3.26.2 The automatic release of the extinguishant shall be initiated by the central Fire and Gas control
panel after receipt of a confirmed 2-out-of-2 (or 2-out-of-3) fire signal.

3.26.3 Facilities shall be provided to inhibit the automatic operation of the extinguishant system before
entry is made to areas protected by an automatic system. In addition to any mechanical interlocks
that may be applied, the operation of the gas release system shall be inhibited by the central Fire
and Gas control panel on receipt of an entry signal. This shall be indicated in the main control
room and the fire station.

3.26.4 A pre-warning (audible and visual) signal shall be given by the central fire and gas monitoring
system at the release location before the release of the extinguishant. The interval between the
alarm and release of extinguishant shall be adjustable to correspond to the time necessary for
complete evacuation of the area. The minimum time period shall be 6 seconds.

3.26.5 A confirmation of gas release shall be given by the extinguishing system. A discrepancy alarm
shall be given by the central fire and gas monitoring system if this signal is not received.

4.0 MATERIALS

4.1 No copper or copper bearing alloys shall be used where exposure to sour gases may occur.

4.2 Low melting point materials (e.g. brass and aluminium) are unacceptable for the construction of
any housings.

4.3 Cabinet construction shall meet the requirements of GES J.12.

5.0 MANUFACTURE

QA/QC

The Vendor/Contractor shall submit to the Owner, for approval, details of the proposed quality
assurance and Quality Control Plan.

5.1 Identification and Labelling

5.1.1 All Fire Detectors shall be in red housings.

5.1.2 The word FIRE in Arabic and English shall appear at all manual alarm call points.
 GENERAL ENGINEERING SPECIFICATION GES J.24
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5.1.3 All Fire & Gas detectors and associated equipment shall be provided with identification tag plates
and Vendor/Contractor's nameplates.

5.1.4 The identification tag plates shall be stainless steel, engraved or stamped with the equipment Tag
Number and securely attached to the equipment.

5.1.5 The identification tag plate shall not be part of the Vendor/Contractor's nameplate.

5.1.6 All equipment shall be provided with a permanently attached Vendor/Contractor's nameplate
which shall include the following information:

- Vendor/Contractor's Name, Model and Serial Number.

- Date of manufacture (Month/Year).
- Owner's Purchase Order/Contract Number.
- Operating voltage and frequency.
- Hazardous Area certification details.

6.0 INSTALLATION

6.1 Manual Alarm Call Points

6.1.1 Manual alarm call points shall be positioned in such a way that they stand out against the
background. Where sand deposits may impact the alarm performance the Vendor/Contractor may
with Owner's approval, install instrument air purge or suitable alternate for critical applications.

6.1.2 Manual alarm call points shall be installed at intervals of a maximum of 300 ft (90 metres) along
roads in the plant area and a maximum of 600 ft (180 metres) in storage/tankage areas.

6.1.3 Manual alarm call points should preferably be installed at or near hydrants.

6.1.4 Manual alarm call points shall also be installed near or at high risk locations such as pump areas,
manifolds, oil interceptors, motor control centres and jetty heads.

6.1.5 Interior building manual alarm call points shall be so located that no person need normally travel
more than 100 ft (30 metres) to raise an alarm.

6.1.6 Interior manual alarm call points shall be preferably located along regularly used routes, next to
doors, on floor landings, and at exits to the open air. Manual alarm call points shall not be
installed in locations which may be obstructed by, for example, doors when open.

6.1.7 Manual alarm call points shall be mounted at a height of 5 ft (1.5 m) from the floor.

6.1.8 Manual alarm call points shall not be supported by removable steelwork such as handrails. Other
existing metal supports, of permanent nature, may be utilised, otherwise new metal supports shall
be used.

6.1.9 Each manual alarm call point shall have a tag label fixed directly adjacent to it.

6.2 Plant Linear Heat Detectors (Fusible Plastic Tubing)

6.2.1 The cable shall be rigidly supported and mounted to minimise the possibility of coming into
contact with hot surfaces, e.g. pump bodies and to avoid mechanical damage.

6.2.2 Consideration shall be given to maintenance requirements, i.e. the removal of equipment in
arranging the layout and support for the tubing. Routine maintenance shall not require the moving
of the fusible loop tubing.
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6.2.3 The instrument air lines for inter-connections and for connecting the tubing to the instrument air
header shall meet the requirements of GES J.15.

6.3 Plant Linear Heat Detectors (Heat Sensitive Cable)

6.3.1 The fire detection cable shall be rigidly supported and mounted to minimise the likelihood of
mechanical damage.

6.3.2 Consideration shall be given to maintenance requirements, i.e. the removal of equipment in
arranging the layout and support for the cable. Routine maintenance shall not require the moving
of the cable.

6.3.3 The outer end of the cable shall be sealed by an approved method.

6.3.4 The cable shall be rigidly supported and mounted to minimise the possibility of coming into
contact with hot surfaces, e.g. pump bodies and to avoid mechanical damage.

6.4 Infra-red and Ultra-violet Flame Detectors

6.4.1 Flame detectors shall be positioned in such a way that their field of view is not obstructed. A
typical polar diagram showing the relative variation with angle of incidence is shown in Figure 4.

6.4.2 The Vendor/Contractor's recommendation shall be followed in determining the height and location
of the detectors.

6.4.3 Flame detectors shall be mounted such that they are not subjected to vibration and shock.

6.4.4 Flame detectors shall be protected against the effects of rainwater and sunlight.

6.5 Point Smoke Detectors

6.5.1 The positioning of smoke detectors shall, as a minimum, be in accordance with NFPA 72.

6.5.2 Smoke detectors which are not visible (e.g. above ceiling tiles) shall have a second tag label fixed
to the nearest visible position to the detector.

6.5.3 Ionisation type detectors shall be clearly identified as containing a radio-active source.

6.5.4 The detectors shall not be mounted directly on removable ceiling tiles, but they shall be supported
by an independent framework.

6.6 Point Heat Detectors

6.6.1 The positioning of heat detectors shall, as a minimum, be in accordance with NFPA 72.

6.6.2 Heat detectors which are not visible (e.g. above ceiling tiles) shall have a second tag label fixed to
the nearest visible position to the detector.

6.6.3 The detectors shall not be mounted directly on to removable ceiling tiles, but shall in such cases be
supported by an independent framework.

6.7 Air Sampling Type Smoke Detectors (VESDA)

6.7.1 VESDA smoke detectors are sensitive to air flow changes, and therefore should not be finally
located and installed until the air flow patterns have been established.
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6.7.2 The installation design of VESDA systems shall be the responsibility of the Vendor/Contractor.
The Vendor/Contractor shall be responsible for issuing detailed installation requirements.

6.8 Beam-type Smoke Detectors

6.8.1 Where beam-type detectors are installed in a building with a pitched or "north light" roof then the
installation shall be placed in the apex of the building.

6.8.2 For flat roofed buildings the detectors shall be at ceiling height and with a maximum distance from
side walls or other beam detectors as defined by the Vendor/Contractor.

6.8.3 The structure on which the receiver and transmitter are mounted shall be rigid and vibration free.

6.8.4 The beam shall not be temporarily impeded by objects such as travelling cranes etc.

6.8.5 It is possible for beams to pass through holes in walls, but the hole must not be less than the beam
diameter at the point along the beam path.

6.8.6 Where the area to be covered exceeds that possible with a single detector then multiple detectors
shall be installed at the spacing recommended by the Vendor/Contractor.

6.9 Flammable and Toxic Gas Detectors

6.9.1 Gas detector sensors shall be located in the vicinity of the most likely sources of gas release.
Variables such as prevailing wind direction and wind speed shall be taken into account.

6.9.2 Sensors shall be orientated in a vertical position (pointing downwards). Sensors for heavier than
air gases shall be located between 14 in (350 mm) and 24 in (600 mm) above grade. In enclosed
spaces detectors for lighter than air gases shall be installed high on the ceiling.

6.9.3 The senor shall be rigidly supported and properly located, or protected to prevent mechanical
damage.

6.9.4 The sensors shall have a weather protection shroud fitted with a nozzle to facilitate in-situ
calibration.

6.9.5 Where "one man" calibration units are used, the sensor shall be mounted directly on the
transmitter housing if the transmitter is located in a convenient position for calibration. If the
sensor is not in a convenient position, the sensor shall be directly mounted on a junction box with
connections to a transmitter located at a convenient location.

6.9.6 The sensor mounting shall be suitable for direct connection to the junction box or transmitter.
Protective glands shall be fitted at each end of the cable. All gland sizes and screw threads shall be
compatible with the junction box. Silicon free grease shall be applied to keep the connections
waterproof.

6.9.7 Sensors which are not accessible for calibration/testing shall have a ¼" stainless steel tube taken
from the weather protection shroud to a suitable location for the connection of the calibrating gas.
The tube shall be terminated by a ¼" quick connect coupling.

6.9.8 HVAC air intakes shall be provided with both hydrocarbon and toxic gas detectors.

6.9.9 The sensors can be poisoned by lead (leaded fuel, paints), silicone compounds (lubricants, polish,
paints, etc), metal vapours (welding), and some chlorinated hydrocarbons (trichloroethylene,
methylene chloride). The sensors shall therefore be bagged or sealed whenever welding, cleaning
or painting is carried out in the vicinity of the sensors.
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6.9.10 Each detector shall be fitted with an activated filter to prevent the poisoning of the catalyst.

7.0 INSPECTION

7.1 Visual Inspection

7.1.1 Each component of the fire and gas system shall be visually inspected by the Owner, and/or the
nominated Inspector at the Vendor/Contractor's premises prior to shipment.

7.1.2 The Vendor/Contractor shall ensure that the inspection is carried out in accordance with the
Quality Assurance Procedure previously approved by the Owner.

7.1.3 All panels, mimic panels and system cabinets shall be checked for conformity to the Purchase
Order/Contract and approved Vendor/Contractor's drawings.

7.1.4 The inspection shall, as a minimum, include a visual inspection of the general appearance,
mechanical assembly, and full dimensional checks.

7.1.5 The inspection shall include a check on the mechanical operation of slides and doors, check wiring
type, size, segregation, ferruling and crimp connections, verify that component types, ratings and
values are as per approved drawings.

7.1.6 All installed power supplies shall be checked for suitability against the specified mains power
supplies.

7.1.7 All system modules shall be checked for their correct location, insertion and identification.

7.1.8 All cabinet and system labels and field device labels and tags shall be checked.

7.1.9 The installed spares shall be checked for quantity and distribution. All components for installation
in hazardous areas shall be checked to ensure the suitability of the protection for the relevant area
classification.

8.0 TESTING

8.1 Heat Soak Test

8.1.2 The heat soak test shall not be carried out until visual inspection and preliminary tests are
complete, and the Owner is satisfied that the Vendor/Contractor's tests have been carried out
satisfactorily.

8.1.3 The serial number of all removable modules shall be noted before the commencement of the heat
soak test.

8.1.4 All cabinet doors shall be closed and all cabinet entries, e.g. gland plates, blanked off to simulate
installed conditions.

8.1.5 Any forced ventilation shall be in operation throughout the heat soak test.

8.1.6 The equipment shall be set to simulate the maximum operational load, i.e. with all I/O set at their
maximum current.

8.1.7 The following temperatures shall be recorded during the test:

 GENERAL ENGINEERING SPECIFICATION GES J.24
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ambient temperature of the heated enclosure;
the maximum temperature at selected points within the system.

8.1.8 The temperature of the heated enclosure shall be cycled between 120°F (50°C) and factory
ambient at least four times during a 48-hour period.

8.1.9 Owner specified random checks shall be made prior, during and on completion of the heat test.
All defects shall be recorded and defective equipment replaced.

8.1.10 The extent of further testing shall with agreed with the Owner and will depend on the type and the
extent of the failures. The Owner reserves the right to request for a complete retest.

8.1.11 Sample insulation checks shall be carried on wiring insulation at a test voltage not exceeding 250
V AC and shall be carried out after the heat test. Equipment which may be damaged by the
insulation check shall be disconnected. Any circuits having an insulation resistance of less than
10 megohms shall be rejected.

8.2 Factory Acceptance Testing

8.2.1 The Vendor/Contractor shall prepare and issue for Owner's approval, a comprehensive test
schedule detailing the method of testing, the procedure for the replacement of faulty equipment
and the expected duration. The Vendor/Contractor shall issue the FAT procedure at least eight (8)
weeks before the planned date of the FAT and give at least three (3) weeks notice of the start of
the FAT.

8.2.2 The Vendor/Contractor shall ensure that the FAT is carried out in accordance with the approved
FAT procedure. Any deviation from the test procedure shall be noted.

8.2.3 Functional test shall be carried out on the complete system with the exception of the fire and gas
field devices. Discrete input/output devices shall be simulated by switches and lamps. Back-up
batteries shall be connected. The Vendor/Contractor shall supply all the test equipment necessary
to carry out the tests.

8.2.4 The input/out simulation test panels, shall include facilities such as end-of-line resistors to
generate line fault failures.

8.2.5 Serial interfaces shall be simulated on PC's by the use of appropriate hardware and software.

8.2.6 Each digital input and analogue input shall be individually activated and checked. The system
response, including alarm display, shall be checked against the "cause and effect" charts and
functional logic diagrams.

8.2.7 Each input shall be checked for the correct operation of the line fault detection system.

8.2.8 The system response, including the initiation of output actions, shall be checked for each input.

8.2.9 On voting systems, multiple input combinations shall be activated and checked.

8.2.10 All panels, mimic panels, and operator's interfaces shall be checked for correctness of the
information displayed and logged. The historical data retrieval facilities shall be checked.

8.2.11 Sample checks shall be carried out at the extremes of the voltage tolerances.

8.3 Field Device Testing and Commissioning

8.3.1 All detectors, detection and protection systems shall be calibrated and fully functionally tested
during the commissioning. All system functions and faults alarms shall be tested.
 GENERAL ENGINEERING SPECIFICATION GES J.24
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Rev 0 1999

8.3.2 Gas ampoules shall be used for the calibration of H2S detectors and calibrated gas cylinders for
flammable gas detectors.

8.3.3 A smoke test shall be carried out in all areas which have smoke detection using smoke cans. The
test shall be carried out with all mechanical, ventilating systems operational.

9.0 DOCUMENTATION

9.1 Introduction

9.1.1 This section covers the documentation required for the design selection, fabrication, inspection
and testing for Fire & Gas instrumentation and systems.

9.1.1 Owner Supplied Data

The following information shall be supplied to the Vendor/Contractor by the Owner.

- A design specification which identifies the type, general location and operation of the fire
and gas system specific to the project.

- Cause and Effect charts showing, as a minimum, the type of detector or other initiating
device, alarm requirements, voting arrangements for control action initiation, executive
actions and interfaces with other systems.

- Plot plans showing the location of major plant items and building layouts.

9.1.2 Vendor/Contractor Data

The detailed list of documents that are required is attached to the Purchase Order/Contract.
However, as a minimum the following listed documents shall be provided by the
Vendor/Contractor:

- Functional Logic Diagrams reflecting the requirements of the Cause and Effect charts.
- System reliability/availability calculations.
- Approved dimensional General Arrangement drawings of all system cabinets, consoles
and peripherals.
- Completed Data Sheets.
- System layout drawings.
- Internal wiring and termination drawings.
- Field I/O termination drawings.
- Power distribution drawings.
- Earthing layout and connections.
- System cable schedule.
- System inter-connection drawings.
- Installation drawings for the total system and detection/protection equipment.
- FAT test procedures.
- Vendor/Contractor's test manuals.
- Operation, Installation and Maintenance manuals.
- Spare Parts List.
- Detector General Arrangement Drawings.
- Protection Systems General Arrangement Drawings.
- Detector interconnection drawings.
- Special tools list.
- Calibration equipment details.
 GENERAL ENGINEERING SPECIFICATION GES J.24
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Rev 0 1999
9.2 Schedules and Reports

The Vendor/Contractor shall supply a schedule showing the documents for review and approval,
proposed sub-contractors and material procurement, and a production/ fabrication programme.

9.3 Data and Calculations

The Vendor/Contractor shall submit all calculations and data for acceptance by the Owner within
the period specified by the Purchase Order/Contract. The calculations and data shall become the
property of the Owner after acceptance.

9.4 Drawings

The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to
the Owner and/or Inspection Authority for review and approval.

9.5 Final Records, Documents and Manuals

Two (2) copies of the Data book and six (6) copies of the Installation, Operating and Maintenance
manual shall be supplied with the equipment.

9.6 Certificates

Certificates issued by an approved certifying authority covering the use of the devices in
hazardous areas shall be supplied with each device.

10.0 PRIOR TO SHIPMENT

10.1 Painting and Coatings

Surface preparation, painting and painting materials shall be in accordance with GES X.06.

Painting and protective coatings shall take into account the methods of transport to be used (e.g.
deck cargo).
 GENERAL ENGINEERING SPECIFICATION GES J.24
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Rev 0 1999
10.2 Spares

The Vendor/Contractor shall submit with his proposal, a priced list of recommended spares for
start-up and two years operation.

10.2.1 Field Devices

The Vendor/Contractor shall include, calibration gases and smoke cans and calibration tools for
commissioning the fire and gas field devices.

10.2.2 Central Fire and Gas Control Panel

(a) The control panel shall have 25% installed spare capacity. The spare points shall be
distributed through the input/output modules. The spares shall be fully wired from the
field terminals within the panel to the I/O cards.

(b) The system shall have sufficient spare I/O slots to allow for a 10% increase in capacity.
All spare slots shall be provided with blanking plates.

(c) The Vendor/Contractor shall supply with the system the spare parts that may be required
during the commissioning of the system. These shall include at least one of each type of
system module, including power units and consumables such as fuses, panel wiring,
wiring installation material and LEDs.

10.3 Packing and Storage

10.3.1 This section describes the minimum requirement for the preservation and protection of the Fire &
Gas instrumentation during sea and land transportation and storage, prior to installation.

10.3.2 The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of
24 months shall be assumed. Packing shall be suitable for sea freight.

10.3.3 The system and system components shall be securely packaged so that they are protected against
external damage during transit.

10.3.4 Panels and system cabinets shall be packaged in moisture-proof sealed containers containing a
desiccant.

10.3.5 Where multiple crates or packages are used, then each shall be individually numbered and the
number clearly marked on the outside of crate or package. A packing list relating the crate or
package number to the contents shall accompany the consignment.

10.3.6 Machined or threaded exterior surfaces shall be protected during shipment.

10.3.7 All electronic circuit boards and modules which are not securely locked in place shall be removed
from the system before shipment.

10.3.8 All loose electronic circuit boards and modules shall be packaged in sealed moisture-proof bags.

10.4 Shipping

The Fire & Gas instrumentation shall not leave the Vendor/Contractor's works for shipment, until
the release has been approved by the Owner's Inspector.

10.5 Warranty
 GENERAL ENGINEERING SPECIFICATION GES J.24
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Rev 0 1999
10.5.1 The Vendor/Contractor shall warrant all materials and services supplied against any defect, for a
minimum period of 12 months after commissioning, or 24 months from the date of delivery to the
site, whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

10.5.2 Should any item be found defective the Vendor/Contractor shall be responsible for all costs
associated with restoring the equipment to the standard equivalent to that specified in the Purchase
Order/Contract.

10.5.3 The Vendor/Contractor shall undertake to carry out the repair or replacement in an expeditious
manner.The terms and conditions of the Warranty shall be additional to any other requirements
specified in the Purchase Order/Contract.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES L.02

POWER AND CONTROL CABLES

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC specification 4
1.3 Data Sheets 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 8

3.0 DESIGN AND PERFORMANCE 9

3.1 Environmental Conditions 9

3.2 Codes and Standards 9
3.3 Voltage and Frequency (Supply) 13
3.4 Application and Selection 14
3.5 Cable Design Considerations 14
3.6 Insulating Materials 15

4.0 CONSTRUCTION 16

4.1 Conductors 16
4.2 Conductor Screening 16
4.3 Insulation 16
4.4 Conductor (Core) Identification 17
4.5 Lead Sheath 17
4.6 Bedding 17
4.7 Armour 18
4.8 Jacket (Outer Covering) 18
4.9 Environment 18
4.10 Temperature 19
4.11 Conductor Insulation Shield 19
4.12 Sheath Damage and Minimum Bending Radius 19
4.13 Cable Support Spacing 19
4.14 Cable Specification Sheets 19
4.15 Cable Specifications Index 21

5.0 NEMA/IEC DIFFERENCES 64

5.1 General 64
5.2 Salient Differences 64

SEC TITLE PAGE

6.0 INSPECTION 66
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6.1 Procedures 66
6.2 Scope 67
6.3 Nameplates (on Cable Drums) 67

7.0 TESTING 67

7.1 Statutory Tests 67

7.2 Factory Acceptance testing 69
7.3 Test Procedures 69
7.4 Site Acceptance Test Requirements 69
7.5 Test Certificates 70
7.6 Test Equipment 70

8.0 DOCUMENTATION 70

8.1 Introduction 70
8.2 Schedules and Reports 71
8.3 Data and calculations 71
8.4 Drawings 72
8.5 Final Records, Document & Manuals 72

9.0 PRIOR TO SHIPMENT 73

9.1 Painting and Coatings 73

9.2 Spares 73
9.3 Packing and Storage 73
9.4 Shipping 73
9.5 Warranty 74

DATA SHEETS (2)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification defines the minimum requirements for the design, construction, inspection and testing for
Electric Power and Control Cables up to 36 kV; the specification could be utilised for power cables above
36 kV but only after consultation with the Owner.

1.1.2 The specification applies to cables for refineries, onshore oil and gas installations and processing facilities,
including cables purchased either directly or as part of a package.

1.1.3 This specification is generally based on ANSI/NEMA Standards. The Vendor/Contractor shall comply
fully with the provisions laid down in this specification. Any exception must be authorised in writing by
the Owner as failure to do so shall indicate full compliance; any remedial work then necessary, shall be at
the Vendor/Contractor's expense.

1.1.4 In the event of any conflict between this specification and the Data Sheets, or with any of the applicable
codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification before proceeding with the work.

1.1.5 This General Engineering Specification will form part of the Purchase Order/Contract, together with any
Data Sheets, drawings or other attachments.

Exclusions

Instrument cables are excluded; refer to GES J.16.

Telecommunications cables are also excluded; refer to GES T.07 and T.10.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES A.06 Site Data

GES B.12 Heating, Ventilation and Air Conditioning

GES J.16 Instrument Cable and Cabling

GES L.34 Electrical Equipment in Contaminated Environments

GES T.07 Optical Fibre Cable Systems

GES T.10 Local Telephone Cabling Systems

1.3 Data Sheets

The technical data supplied by the Owner for the cables is given on the Data Sheets which are included at
the end of this specification and include reference to the 'CT' cable types which precisely specify the cables
required.

The Vendor/Contractor shall complete of the Data Sheets with the remaining information.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Ampacity (Current Rating)

The maximum load current that can be carried by a cable under the defined conditions of installation
without exceeding the limiting conductor temperature rise.

Armour

A metallic layer primarily used for mechanical protection of the cable.

Cable Shield (Screen)

A metallic layer.

Fire Resistant Cable

Cable constructed to allow continued normal operation for a specified time when exposed to combustion.

Fire Survival Cable

Cable constructed of materials that will still be suitable for continuous operation after exposure to heat of a
specified temperature and duration.

Flame Retardant Cable

Cable constructed of materials which will not assist the spread of flame when the cable is exposed to
combustion. Fire resistant cable built to this standard will also be flame retardant.

Insulation Shield

A semi-conducting polymeric (non-metallic) layer.

Lay

The lay of any helical element of a cable is the axial length of a turn of the helix of that element.

Nominal System Voltage

The rms "phase to phase" or "phase to neutral" voltage by which the system is designated and at (or near)
which level, the system normally operates. (See also 'U' and 'UO' overleaf).

Routine Tests

Tests made on all completed lengths of cable or as appropriate during manufacture.

Sample Tests

Tests made on samples of completed cable or components taken from a completed cable. The tests shall be
performed on one drum for every batch of up to ten despatch drums of one conductor size and type of
cable, or as agreed between Owner and Vendor/Contractor.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Type Tests

Tests made on specimens of cables as produced by a specific Vendor/Contractor to demonstrate the

Vendor/Contractor's ability to satisfactorily produce a range of cables designed to comply with the
requirements of this standard. These tests, after they have been successfully completed, need not be
repeated unless changes are made which might affect compliance with the test requirements.

Jacket (Sheath)

Outer covering of a cable which may be metallic or non metallic according to the conditions of installation.

Shielding

Shielding of an electric power cable is the practice of confining the dielectric field of the cable to the
insulation of the conductor or conductors. It is accomplished by means of a conductor stress control layer
and an insulation shield.

Substantially Compact

'Substantially compact' to meet the requirements for Division 1 (class I, II or III locations) enclosures is
taken as being tightly filled enough to prevent any escape of material or hot gas likely to cause an explosion
outside the enclosure. The concept of 'substantially compact' is a consideration which allows suitable
cables to be terminated directly into Division 1 enclosures without the need for a barrier gland.

Triplex (Trefoil)

Three single core conductors installed in close contact and normally arranged as a group of three in a "One
up, Two down" formation.

For power cables, the power-frequency voltage between conductors for which the cable is designed.

Uo

For power cables, the power-frequency voltage to earth for which the cable is designed.

Utilisation Voltage

The rms "phase to phase" or "phase to neutral" voltage at the line terminals of utilisation equipment.

Oxygen Index

The minimum concentration of oxygen in an oxygen/nitrogen mixture in which the material will burn.

Note: Air contains 21% oxygen and material with an oxygen index greater than 26% is said to be self-
extinguishing.

Temperature Index

That temperature at which the oxygen index of the material becomes 21.

CSPE (CSP)
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999

Chlorosulphonated Polyethylene

ELAST

Halogen Free Elastometer Sheathing Material

EN

European Committee for Electrical Standards

EPDM

Ethylene Propylene Diene Monomer

HOFR

Heat & Oil Resisting, Flame Retardant

ICEA

Insulated Cable Engineers Association, Inc.

IEC

International Electrotechnical Commission

MEGOLON

Thermoplastic Halogen Free Sheathing Compound

POLYRAD XT

Irradiated Polyolefin Compound

SWA

Single Wire Armour or Steel Wire Armour

TP

Thermoplastic EVA Bedding and/or Sheathing

AWA Aluminium Wire Armour AWG American Wire Gauge

COR CU Corrugated Copper CSA Cross Sectional Area
CUWB Copper Wire Band EMA Ethylene Methyl Acrylate
EPR Ethylene Propylene Rubber EVA Ethylene Vinyl Acetate
FLEX Flexible GSWB Galvanised Steel Wire Braid
HCl Hydrogen Chloride IMP Irradiated Modified Polyolefin
 GENERAL ENGINEERING SPECIFICATION GES L.02
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IS Intrinsically Safe ISO International Standards Organisation
LDF Low Density Foam LSLH Low Smoke Low Halogen
MI Mineral Insulated MODP Modified Polyolefin
MP Modified Polyester MT MICA Glass Tape
NBR Nitrile Butadiene Rubber PBWB Phosphor Bronze Wire Braid
PE Polyethylene PTFE Polytetra Fluoro Ethylene
PTP Polyethylene Terephtalte PVC Polyvinyl Chloride
PVDF Polyvinylidene Fluoride SCR Screened
SOL CU Solid Copper STR CU Stranded Copper
XLPA Cross Linked Polyalkene XLPE Cross Linked Polyethylene

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment.

Vendor

The company supplying the equipment.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment has been
designed, constructed, inspected and tested in accordance with the requirements of this specification and
the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment has been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN AND PERFORMANCE

3.1 Environmental Conditions

3.1.1 External Environment

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999

These conditions are fully detailed in GES A.06, and cover the principal site conditions affecting the
electrical power and control cables including maximum and minimum ambient temperature, dust, humidity
and altitude etc.

3.1.2 Internal Environment

Electrical Power and Control Cables may be housed in an enclosed, air-conditioned equipment room; full
details are given in GES B.12.

Temporary excursions from these limits e.g. during short term power failure, shall be ignored for the
purposes of equipment rating.

3.2 Codes and Standards

3.2.1 General

In general, the requirements specified herein are based on the ANSI/NEMA and other American Codes and
Standards, the most important of which are listed below. Unless otherwise stated, electrical cables and
materials shall comply with these Codes and Standards.

Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and Standards
at the time of order shall be used.

The Vendor/Contractor shall operate and supply certification for a Quality System complying with the
requirements of the ASQ Q9000 Series or BS EN ISO 9000, Part 1 (Design) Part 2 (Production) and Part 3
(Test and Inspection).

3.2.2 US (and Canadian) Codes and Standards

ANSI C2 National Electrical Safety Code

ASQ Q9000 Quality Management and Quality Assurance

ASTM B 193 Test Method for Resistivity of Electrical Conductor Materials

ASTM D 257 Test Method for DC Resistance of Conductance of Insulating Materials

ASTM D 1535 Standard Method of Specifying Colour by the Munsell System

CSA C22.2 - 131 Type 'TECK 90' Cables (Canadian Standards Association)

CSA C22.2 - 174 Cables and Cable Glands for use in Hazardous Locations (Canadian Standards
Association)

CSA C22.2 - 239 Control Cables - 600 volts (Canadian Standards Association)

ICEA P-32-382 Short-Circuit Characteristics of Insulated Cable

ICEA P-45-482 Short-Circuit Performance of Metallic Shielding and Sheaths

ICEA T-28-562 Test Method for Measurement of Hot Creep of Polymeric Insulations
 GENERAL ENGINEERING SPECIFICATION GES L.02
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ICEA T-29-520 Procedure for conducting Vertical Tray Flame Tests with a Theoretical Heat
Input Rate of 210,000 B.T.U./Hour

ICEA T-30-520 Procedure for conducting Vertical Cable Tray Flame Tests with a Theoretical
Heat Input Rate of 70,000 B.T.U./Hour

IEEE 400 Guide for making High-Direct-Voltage tests on Power Cable Systems in the
field

IEEE 525 Guide for Design and Installation of Cable Systems in Substations

IEEE 592 Exposed Semi-conducting shields on High Voltage Cable Joints and Separable
Insulated Connectors

IEEE 835 Power Cable Ampacity Tables

NEMA WC2 Steel Armour and Associated Coverings for Impregnated Paper Insulated Cables

NEMA WC3 Rubber-Insulated Wire and Cable for the Transmission and Distribution of
Electrical Energy

NEMA WC5 Thermoplastic-Insulated Wire and Cable for the Transmission and Distribution
of Electrical Energy

NEMA WC7 Cross-Linked Thermosetting Polyethylene Insulated Wire and Cable for the
Transmission and Distribution of Electrical Energy

NEMA WC8 Ethylene-Propylene-Rubber-Insulated Wire and Cable for the Transmission and
Distribution of Electrical Energy

NEMA WC50 Ampacities including effect of Shield Losses for single conductor Solid
Dielectric Power Cable, 15 kV through 69 kV (Copper and Aluminium
Conductors)

NEMA WC51 Ampacities of Cables in Open-top Cable Trays

NEMA WC53 Standard Test Methods for Extruded Dielectric Power, Control, Instrumentation
and Portable Cables for Test

NEMA WC57 Standard for Control Cables

NFPA 70 National Electrical Code

UL 44 Rubber-Insulated Wires and Cables

UL 493 Thermoplastic-Insulated Underground Feeder and Branch-Circuit Cables

UL 910 Test for Flame-Propagation and Smoke Density Values for Electrical and
Optical Fibre Cables used in spaces transporting Environmental Air

UL 1072 Medium Voltage Power Cables

UL 1569 Metal-Clad Cables

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3.2.3 IEC and other Recommendations

When appropriate, equivalent International Standards which may be used as alternatives are listed below
and may be used with the prior approval of the Owner. Equipment and materials complying with IEC
Recommendations shall be at least equal to the requirements of this specification. The Vendor/Contractor
shall advise full details of any deviations to these requirements in his offer if IEC based standards are
utilised.

BS 5345 (8 Parts)Code of Practice for Selection, Installation and Maintenance of Electrical Apparatus for
use in potentially Explosive Atmospheres

BS 5467 Specification for 600/1000 V and 1900/3300 V Armoured Electric Cables with
Thermosetting Insulation

BS 6004 Specification for PVC-Insulated Cables (non-armoured) for Electric Power and Lighting

BS 6007 Specification for Rubber-Insulated Cables for Electric Power and Lighting

BS 6346 Specification for 600/1000 V and 1900/3300 V Armoured Electric Cables having PVC
Insulation

BS 6387 Specification for Performance Requirement for Cables required to maintain Circuit
Integrity under Fire Conditions

BS 6622 Specification for Cables with Extruded Cross-Linked Polyethylene or Ethylene Propylene
Rubber Insulation for Rated Voltages from 3800/6600 V up to 19,000/33,000 V

BS 6724 Specification for 600/1000 V and 1900/3300 V Armoured Cables having Thermosetting
Insulation with Low Emissions of Smoke and Corrosive Gases when Affected
by Fire

BS 6746 Specification for PVC Insulation and Sheath of Electric Cables

BS 6883 Specification for Elastometer Insulated Cables for Fixed Wiring in Ships

BS 6899 Specification for Rubber Insulation and Sheath of Electric Cables

BS 7211 Specification for Thermosetting Insulated Cables (non-armoured) for Electric

Power and Lighting with Low Emission of Smoke and Corrosive Gases when
affected by Fire

BS 7671 Requirements for Electrical Installations. (IEE Wiring Regulations. 16th Edition)

ERA Report 69-30

Part I Sustained Current Ratings for Paper Insulated Lead Sheathed Cables to BS
6480, Part 1:1969

Part II Sustained current ratings for paper-insulated cables with aluminium

sheath/neutral conductor and three shaped solid aluminium phase conductors
(Consac) to BS 5593:1978

Part III Sustained current ratings for PVC-insulated cables to BS6346: 1969
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Part IV Calculation of cyclic and emergency current ratings for cables laid direct in the
ground or in ducts for cables up to and including 19/33 kV.

Part V Sustained current ratings for armoured cables with thermosetting insulation to
BS 5467:1989 and BS 6724:1986

Part VI Sustained current ratings for cables to BS 5467: 1989 and BS 6724: 1986 in
multi layer groups on trays

Part VII Sustained current ratings for cables to BS 5467: 1989 and BS 6724: 1986 in multi layer
groups on trays.

Part VIII Sustained current ratings for PVC insulated cables up to 70 mm2 to BS 6004:
1984 in mixed groups in painted steel trunking to BS 4678: Part 1: 1971

IEC 60227 (7 Parts) PVC Insulated Cables of Voltages up to 450/750 V

IEC 60228 Conductors of insulated cables

IEC 60331 Fire resisting characteristics of electric cables

IEC 60332-3 Tests on electric cables under fire conditions-Tests on Bunched Wires or Cables

IEC 60502 Extruded solid dielectric insulated power cables for voltages from 1 kV up to 30
kV

IEC 60754 - 1 Test on gases evolved during combustion of electric cables (Determination of
the amount of Halogen Acid Gas involved during the combustion of Polymeric
materials taken from cables)

3.3 Voltage and Frequency (Supply)

Apart from the fact that the USA generally uses 60 Hz rather than the 50 Hz used in European countries
using IEC standards, there is also a difference in the more common Nominal System Voltages as shown
below:

NOMINAL SYSTEM VOLTAGES

Standard Nominal American System Voltages Associated European/UK System Voltages

Low Voltages (see Note 2) Low Voltages
120 120
120/240 208
208Y/120 230
240/120 240
240 254
480Y/277 380
480 415
600 440
600

Medium Voltages (see Note 2) Medium Voltages

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2,400 3,300
4,160Y/2,400 6,600
4,160 11,000
4,800 13,800
6,900 22,000
8,320Y/4,800 33,000
12,000Y/6,930 66,000
12,470Y/7,200
13,200Y/7,970
13,800
20,780Y/12,000
22,860Y/13,200
23,000
24,940Y/14,400
34,500Y/19,920
34,500
46,000
69,000

Note 1 This should not be a problem as cables are made available for a range of voltages rather than a specific
voltage e.g. Electric Power & Control Cables from the UK manufactured for Low Voltage Systems up to
1000 volts (phase to phase) which covers the single and low voltage ranges shown above.

Note 2 Provided the Owner's data clearly specifies on the appropriate space in the Data Sheet the 'U/Uo' system
voltage, the correct cable should be provided by the Vendor/Contractor.

3.4 Application and Selection

(a) For new projects requiring relatively large quantities of cable, preference shall be given to a
selection of PVC flame retardant insulated and jacketed (sheathed) cables for general application
on the plant in all areas except normally manned areas e.g. Control Rooms.

For special applications, e.g. increased oil resistance, where PVC insulated and sheathed cables
are not appropriate, the bedding and outer jacket (sheath) material shall be of CSP.

(b) For fire survival requirements, only MICC is suitable up to the melting point of copper 1981°F
(1083°C). However, its use should be limited due to the hygroscopic nature of the magnesium
oxide insulation which can cause problems if not properly sealed.

(c) For completeness paper insulated cables are referred to, but their use is not recommended as
skilled jointers are required.

(d) Significant advances have been made in the development of EVA cable jackets (sheaths). This
material can meet the very low smoke, halogen and hydrochloric acid emission requirements when
burnt and is also less expensive.

(e) The preferred colour of the outer sheath of cables is black. However, an increasing amount of
cables are being manufactured with a different sheath colour namely grey or white and these may
be considered as acceptable provided that:
 GENERAL ENGINEERING SPECIFICATION GES L.02
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- properties of the cable are not infringed,

- the colour sheath is not used to differentiate between duties of the cables,
- the colour does not infringe any safety codes.

The identification of the individual cores of power cables up to and including 4 core cables will
normally be by means of the colour code. However, the use of numbered cores is acceptable.
(f) Cables supplied must be capable of being glanded into hazardous area certified glands. The use of
very low smoke and acid gas producing cables when burnt within manned areas is a mandatory
requirement. PVC and CSP sheathed cables may enter manned areas so long as cables are not
routed in the control room and other living areas.

3.5 Cable Design Considerations

The selection of cable for particular circuits or feeders shall be based around the following considerations:

(1) Electrical

Dictates conductor size, type and thickness of insulation, correct materials for low-and medium-
voltage designs, consideration of dielectric strength, insulation resistance, specific inductive
capacitance (dielectric constant), and power factor.

(2) Thermal

Compatible with ambient and overload conditions, expansion, and thermal resistance.

(3) Mechanical

Involves toughness and flexibility, consideration of jacketing or armouring, and resistance to

impact, crushing, abrasion, and moisture.

(4) Chemical

Stability of materials on exposure to oils, flame, ozone, sunlight, acids, and alkalis.

3.6 Insulating Materials

3.6.1 Insulations in common use are:

(a) thermosetting compounds, solid dielectric,

(b) thermoplastic compounds, solid dielectric,
(c) paper-laminated tapes,
(d) mineral insulation, solid dielectric granular (Magnesium Oxide).

3.6.2 Insulation Comparison

Heat, aging moisture, and ozone are the most destructive of factors affecting insulations.

(a) Heat Resistance

Generally speaking, the thermosetting materials (XLPE, EPR, CSP etc.) are superior to the
thermoplastic materials (PVC, polyethylene etc).
 GENERAL ENGINEERING SPECIFICATION GES L.02
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(b) Heat Aging

The 302°F (150°C) oven aging shall be used to compare materials with superior heat resistance.
Temperature ratings of insulations in general use show that the thermosetting materials (and paper
insulations) are superior.

(c) Ozone and Corona Resistance

Insulations exhibiting superior ozone resistance under accelerated conditions are silicone,
polyethylene, XLPE, EPR, and polyvinyl chloride.

However, this is not the case with corona discharge. The phenomenon of corona discharge
produces concentrated and destructive thermal effects along with formation of ozone and other
ionized gases. Although corona resistance is a property associated with cables over 600 V, in a
properly designed and manufactured cable, damaging corona is not expected to be present at
operating voltage. Materials exhibiting less susceptibility than polyethylene and XLPE to such
discharge activity are the ethylene propylene rubbers (EPRs).

(d) Moisture Resistance

Insulations such as XLPE, polyethylene and EPR exhibit excellent resistance to moisture.

4.0 CONSTRUCTION

The detailed construction for each of the cables considered for use are as shown in this section.

4.1 Conductors

The conductors in fixed power and control cables shall be of high-conductivity copper or high purity
aluminium and both meet the requirements of ASTM B1-85, B288 and B3.74 or BS 6360, as relevant.

Dependent upon the actual cable type they may be of stranded or solid copper or aluminium. Smaller sizes
are circular in profile, larger conductors being shaped or tightly compacted to reduce their physical size.

4.2 Conductor Screening

Cables for higher-voltage (above 2 kV) incorporate layers of semi-conducting compound around the
conductors to eliminate discharges at the inner surface of the dielectric.

4.3 Insulation

According to its particular standard specification a cable will be insulated with one of the following:

- PVC (polyvinyl chloride),

- XLPE (cross-linked polyethylene),
- Impregnated Paper (non-preferred),
- Magnesium Oxide (MI),
- EPR (Ethylene Propylene Rubber).

4.3.1 PVC is a clean, easy to handle material with good electrical characteristics and reasonable resistance to a
range of possible contaminants such as water, oils and chemicals. It is inherently flame-retardant and is
suitable for a maximum continuous conductor operating temperature of 158°F (70°C).
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.3.2 XLPE matches all the above attributes but goes a stage or two further. The good qualities of polyethylene
are retained but at high temperatures the toughness and physical properties are improved. The continuous
current ratings of XLPE insulated cables are based upon a maximum conductor temperature of 194°F
(90°C) as opposed to 158°F (70°C) for PVC insulated types.

Short-circuit ratings are also higher, XLPE accepting 482°F (250°C) as a final conductor temperature at the
end of a short circuit compared with 284/320°F (140/160°C) for PVC insulated cables. As a result, in
situations where conductor size is governed by current rating rather than voltage drop, it may be possible to
use a smaller conductor size.

Paper insulation consists of layers of paper tapes applied helically. Insulating papers are carefully selected
to ensure a combination of physical and electrical characteristics, each defined by strict specification and
testing. To complete the insulating process the single cores of laid-up cables are dried under accurately
controlled conditions of vacuum and temperature, then thoroughly impregnated with compound.

Magnesium Oxide is only utilised in MI cable being an inert substance with a good fire performance.

EPR is one of the polymers EPM and EPDM which give a good performance being suitable for continuous
operation at 194°F (90°C).

4.4 Conductor (Core) Identification

4.4.1 Power Cables

NEMA Standards allow the use of 'any suitable means' for identifying power cable conductors and the
colours available as standard shall be accepted. IEC cables shall be identified as follows:

XLPE and PVC cables have coloured cores for cable up to 2 kV.

Number of Conductors (Cores) Stranded or Solid conductors

Single Black
Two Red,black
Three Red,yellow,blue
Four Red,yellow,blue,black

Black denotes the neutral and the other colours the phase conductors in two, three or four core cable.

XLPE cables above 2000 volts shall have natural coloured insulation. Identification is provided by means
of longitudinally applied marker tapes coloured red, yellow and blue for the 3 cores.

Paper insulated cables have taped cores printed with numerals.

4.4.2 Control Cables

Multicore (5 and above) cables preferably shall have printed numerals to identify each core on a single
colour background since this is acceptable for both NEMA and IEC standards.

4.5 Lead Sheath

Paper insulated cables shall incorporate a metallic barrier against moisture and/or corrosive contaminants.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Lead alloys possess suitable characteristics as a sheathing material important both in manufacturing and
installation and for cables buried in the ground, the excellent corrosion resistant properties are necessary.

4.6 Bedding

A layer of tape or extruded PVC around the core assembly (or lead sheath as appropriate) shall separate the
heart of the cable from (and provides a secure bedding for) the metallic armour. In the range of fire
performance, cables as indicated in NFPA 70 or if relevant to BS 6724 a special LSF (low smoke and
fume) compound shall be used.

Paper cables may alternatively be provided with a composite layer of textile beddings and servings
comprising combinations of bitumenized paper, cotton and hessian tapes treated with bitumen compound.

4.7 Armour

Single wire armour is necessary to guard against mechanical damage to the cable and shall meet the
requirements of NEMA WC2.

Single wire armour consisting of galvanised steel wires shall be applied spirally over the bedding, and
where necessary, shall include tinned copper wires to increase the conductance.

Alternatively, armour shall take the form of braided, interlocking spirally applied wires, strips of
aluminium, or tapes of steel.

Single core cables for ac systems shall never be provided with steel armour because of its effect in
increasing the losses. Where necessary, however, suitable non-magnetic protection shall be provided.

4.8 Jacket (Outer Covering)

The standard form of protection for unarmored and armoured cables shall be an extruded PVC jacket.

For enhanced fire performance requirements, special additives shall be included to achieve:

(a) reduced flame propagating properties,

(b) reduction in the quantity of hydrogen chloride gas emission,

(c) reduced emission of smoke and fumes using a low smoke and low fume (LSF) jacket for high risk
areas.

The oxygen index of both bedding and sheath will not be less than 30.

For very low smoke applications EVA (or equal) shall be utilised.

Note:

The outer jacket shall be marked with the manufacturer's name, voltage, rating, number of conductors and
size, minimum installation temperature, hazardous area approval and cable trade name.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.9 Environment

All cables covered in this specification can be used both indoors or outdoors as indicated on the individual
cable Data Sheets, but their burial without metal sheaths shall be avoided as follows:

(a) unarmored cables are not recommended for laying direct in the ground or installing in hazardous
(classified) areas,

(b) cables for laying direct in the ground, particularly in sustained wet conditions, shall have extruded
bedding,

(c) for installations where there is water-logging or where it is likely to occur, advice shall be
obtained from the Vendor/Contractor as it may be desirable to utilise an alternative type of cable.

Reference shall be made to NFPA 70 as numerous conditions of installation are detailed therein.

4.10 Temperature

To avoid risk of damage during handling, cables should only be installed when the cable and the ambient
temperatures have remained above 32°F (0°C) for the last 24 hours, or when special precautions have been
taken to maintain the cable above this temperature.

LSF cables are more flexible than PVC at low temperatures thus allowing the cable to be installed at
temperatures down to 14°F (-10°C).

4.11 Conductor Insulation Shield

Cables rated 5 kV and above shall be provided with conductor insulation shield. Single conductor cable
insulation shield shall consist of extruded semiconducting insulation shield and copper wire insulation
shield acting as a ground conductor.

In multiconductor cables, insulation shield shall consist of extruded semi conducting insulation shield and a
helical applied overlapping copper tape insulation shield.

4.12 Sheath Damage and Minimum Bending Radius

Care shall be taken to ensure that the oversheath is not damaged during installation. This is especially
important where aluminium armour is used since ingress of moisture could lead to corrosion and ultimate
loss of earth continuity.

Cables shall not be bent during installation to a radius smaller than that recommended in the relevant
Standard. Wherever possible larger radii shall be used.

4.13 Cable Support Spacing

As recommended in NFPA 70 or the latest edition of the IEE Regulations (BS 7671) as relevant.

4.14 Cable Specification Sheets

4.14.1 Introduction - Selection of Cables

The following cable specification sheets are compiled according to applications. It is not the intent to
impose a demaracation in usage and the most suitable cable shall be selected irrespective of the grouping.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.14.2 Cable Specifications Index by the Usage

The cable specifications index is summarised the table below. The specification sheets following this Index
are identified by the Cable Type ("CT") and shall be used to specify cables for an application.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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CABLE SPECIFICATION INDEX BY THE USAGE

CABLE USE ABBREVIATION SPEC. NO.

MV 2 kV and above Distribution;

Excluding Continuously Manned

Areas (Control Room):

Incr. Oil Res & Flexibility STR CU/EPR/CSP/PBWB/CSP or STR CU/EPR/CSP/GSWB/CSP CT1

General Use STR CU/XLPE/PVC/AVA/PWL or STR CU/XLPE/PVC/SWA/PVC CT2

General Use STR CU/EPR/PVC/AWA/PVC or STR CU/EPR/PVC/SWA/PVC CT3

LV Distribution & Control;

Excluding Continuously Manned

Areas
CT4

Non Fire Survival Incr. Oil Res. & STR CU/EPR/CSP/PBWB/CSP or STR CU/EPR/CSP/GSWB/CSP

Flexibility CT6

CT5

General Use STR CU/XLPE/PVC/AWA/PVC or STR CU/XLPE/PVC/SWA/PVC CT21

General Use STR CU/PVC/PVC/AWA/PVC or STR CU/PVC/PVC/SWA/PVC

General Use SINGLE CORE or MULTICORE TECK CT7

Fire Survival STR CU/MT/EPR/EPDM/PBWB/CSP or STRCU/MT/EPR/EPDM/GSWB/CSP

LV Distribution & Control in

Continuously Manned Areas

(Control Room):

Lighting, Power & Control STR CU/EPR/EVA/PBWB/EVA or STR CU/EPR/EVA/GSWB/EVA CT16

Non Fire Survival Armoured STR CU/EPR/EVA CT18

Non Fire Survival Unarmored

Lighting, Power & Control STR CU/MT/EPR/EVA/PBWB/EVA or STR CU/MT/EPR/EVA/GSWB/EVA CT17

Fire Survival Armoured STR CU/MT/EPR/EVA CT19

Fire Survival Unarmored

Lighting, Power & Control SOL CU/MI/CU-SHEATH CT8

Fire Survival MICC SOL CU/MI/CU-SHEATH/EVA CT9

Fire Survival MICC

LV Distribution & Control

Areas with heavy oil contamination:

Stranded STR CU/EPR/NBR.PVC/PBWB/NBR.PVC or STR CU/EPR/NBR.PVC/GSWB/NBR.PVC CT10

Flexible FLEX CU/EPR/NBR.PVC/PBWB/NBR.PVC or FLEX CU/EPR/NBR.PVC/GSWB/NBR.PVC CT11

Battery Terminal Interconns FLEX CU/EPR/CSP CT12

Cathodic Protection STR CU/POLYRADXT/PBWB/POLYRADXT CT13

Earthing:

Increased Oil Resistance &

Flexibility STR CU/EPR/CSP CT14

 GENERAL ENGINEERING SPECIFICATION GES L.02
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CABLE USE ABBREVIATION SPEC. NO.

General Use STR CU/PVC CT15

LV Distribution & Control

Continuously Manned Areas:

(if increased cost justified)

Non-Fire Survival Armoured STR CU/MP/GSWB/IMP CT20

Note: Conductor (core) sizes in k.c.mil are mathematical equivalents to metric (mm2) sizes; See Section 5.2.2 for commercially available k.c.mil sizes
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15 Cable Specification Index Page

4.15.1 CT1: MV, 2 kV and above Grade 27

4.15.2 CT2: MV, 2 kV and above Grade 29

4.15.3 CT3: MV, 2 kV and above Grade 31

4.15.4 CT4: LV, 0.6/1.0 kV Grade 33

4.15.5 CT5: LV, 0.6/1.0 kV Grade 36

4.15.6 CT6: LV, 0.6/1.0 kV Grade 38

4.15.7 CT7: LV, 0.6/1.0 kV Grade 40

4.15.8 CT8: LV, 750 V (Heavy Duty) Grade MICC 42

4.15.9 CT9: LV, 750 V (Heavy Duty) Grade MICC 43

4.15.10 CT10: LV, 0.6/1.0 kV Grade 45

4.15.11 CT11: LV, 0.45/0.75 kV Grade, Flexible 48

4.15.12 CT12: LV, 0.6/1.0 kV Grade, Flexible 51

4.15.13 CT13: LV, 0.6/1.0 kV Grade 52

4.15.14 CT14: LV, 0.6/1.0 kV Grade 54

4.15.15 CT15: LV, 0.6/1.0 kV Grade 56

4.15.16 CT16: LV, 0.6/1.0 kV Grade 57

4.15.17 CT17: LV, 0.6/1.0 kV Grade 60

4.15.18 CT18: LV, 0.6/1.0 kV Grade 63

4.15.19 CT19: LV, 0.6/1.0 kV Grade 64

4.15.20 CT20: LV, 0.6/1.0 kV Grade 65

4.15.21 CT21: LV, 0.6/1.0 kV Grade 67

 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.1 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT1

TYPE : MV, 2 kV and above Grade

ABBREVIATION : Single Core STR CU/EPR/CSP/PBWB/CSP

Multicore STR CU/EPR/CSP/GSWB/CSP

USE : MV (High Voltage) Distribution where increased oil resistance

and flexibility are required (excluding continuously manned
areas).

JACKET (SHEATH) : Red preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.
Cores - Single colour coded individually identified (Section 4.4).

CONSTRUCTION : Stranded tinned annealed copper conductors.

Semi-conducting, non-metallic tape or extruded layer, screen.
Ethylene Propylene Rubber Insulation.
Semi-conducting, non-metallic tape or extruded layer, screen
with lapped copper tape.
Chlorosulphonated Polyethylene bedding to NEMA WC3 (BS
6883 Type B).
Single core - Phosphor Bronze Wire Braid Armour.
Multicore - Galvanised Steel Wire Braid Armour.
Chlorosulphonated Polyethylene Jacket (oversheath) to
NEMA WC3 (BS 6883 type B).

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature ≥ 482°F (250°C).
PROPERTIES HCl Emission ≤ 5% by weight of compound at
1472°F (800°C).
NEMA WC3 Part 6 (IEC 332 - Part 3 Category A, Reduced
Propagation).

STANDARDS & : USA - NEMA WC3/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6883 Elastomer insulated cables for fixed wiring
in ships and on mobile and fixed offshore units.

4.15.1 (Cont/d) Page 2 of 2

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TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT1
MATERIAL NO. NO. OF CSA MATERIAL NO. NO. OF CSA

CORES k.c.mil(mm2) CORES k.c.mil/(mm2)

CT1/1 1 138 (70) CT1/11 3 50 (25)

CT1/2 1 188 (95) CT1/12 3 69 (35)

CT1/3 1 237 (120) CT1/13 3 99 (50)

CT1/4 1 296 (150) CT1/14 3 138 (70)

CT/5 1 365(185) CT1/15 3 188 (95)

CT1/6 1 474 (240) CT1/16 3 237 (120)

CT1/7 1 592 (300) CT1/17 3 296 (150)

CT1/8 1 790 (400) CT1/18 3 365 (185)

CT1/9 1 987 (500) CT1/19 3 474 (240)

CT1/10 1 1244 (630) - - -

 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.2 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT2

TYPE : MV, 2 kV and above Grade

ABBREVIATION : Single Core STR CU/XLPE/PVC/AWA/PVC

Multicore STR CU/XLPE/PVC/SWA/PVC

USE : MV (High Voltage) Distribution in general use (excluding

continuously manned areas).

JACKET (SHEATH) : Red preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.
Cores - Single colour coded individually identified (Section 4.4).

CONSTRUCTION : Stranded tinned annealed copper conductors.

Semi-conducting, non-metallic tape or extruded layer,screen.
Cross-linked polyethylene Insulation.
Semi-conducting, non-metallic tape or extruded layer, screen
with lapped copper tape.
Polyvinyl Chloride bedding.
Single core - Single Aluminium Wire Armour.
Multicore - Single Galvanised Steel Wire Armour.
Polyvinyl Chloride Jacket (oversheath).

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature ≥ 572°F (300°C).
PROPERTIES HCl Emission ≤ 17% by weight of compound at
1472°F (800°C).
NEMA WC5 Part 6 (IEC 332 - Part 3 Category A, Reduced
Propagation).

STANDARDS & : USA - NEMA WC5/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
BS/IEC - BS 6622 - for semi-conducting and metallic screens.
BS/IEC - BS 6899 - for XLPE insulation, type GP 5.
BS/IEC - BS 6746 - for hard PVC sheath, type TM 1.
BS/IEC - IEC 502 - for construction, dimensions & tests.
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4.15.2 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT2
MATERIAL NO. NO. OF CORES CSA

k.c.mil(mm2)

CT2/1 1 138 (70.0)

CT2/2 1 188 (95.0)

CT2/3 1 237 (120.0)

CT2/4 1 296 (150.0)

CT2/5 1 365(185.0)

CT2/6 1 474 (240.0)

CT2/7 1 592 (300.0)

CT2/8 3 50 (25.0)

CT2/9 3 69 (35.0)

CT1/10 3 99 (50.0)

CT1/11 3 138 (70.0)

CT1/12 3 188 (95.0)

CT1/13 3 237 (120.0)

CT1/14 3 296 (150.0)

CT2/15 3 365 (185.0)

CT2/16 3 474 (240.0)

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4.15.3 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT3

TYPE : MV, 2 kV and above Grade

ABBREVIATION : Single Core STR CU/EPR/PVC/AWA/PVC

Multicore STR CU/EPR/PVC/SWA/PVC

USE : MV (High Voltage) Distribution in general use (excluding

continuously manned areas).

JACKET (SHEATH) : Red preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.
Cores - Single colour coded individually identified (Section 4.4).

CONSTRUCTION : Stranded tinned annealed copper conductors.

Semi-conducting, non-metallic tape or extruded layer,screen.
Cross-linked polyethylene Insulation.
Semi-conducting, non-metallic tape or extruded layer, screen
with lapped copper tape.
Polyvinyl Chloride bedding.
Single core - Single Aluminium Wire Armour.
Multicore - Single Galvanised Steel Wire Armour.
Polyvinyl Chloride Jacket (oversheath).

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature ≥ 572°F (300°C).
PROPERTIES HCl Emission ≤ 17% by weight of compound at
1472°F (800°C).
NEMA WC5 Part 6 (IEC 332 - Part 3 Category A, Reduced
Propagation).

STANDARDS & : USA - NEMA WC5/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
BS/IEC - BS 6622 - for semi-conducting and metallic screens.
BS/IEC - BS 6899 - for EPR insulation, type GP 5.
BS/IEC - BS 6746 - for hard PVC sheath, type TM 1.
BS/IEC - IEC 502 - for construction, dimensions & tests.
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4.15.3 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT3
MATERIAL NO. NO. OF CORES CSA

k.c.mil(mm2)

CT3/1 1 138 (70.0)

CT3/2 1 188 (95.0)

CT3/3 1 237 (120.0)

CT3/4 1 296 (150.0)

CT3/5 1 365(185.0)

CT3/6 1 474 (240.0)

CT3/7 1 592 (300.0)

CT3/8 3 50 (25.0)

CT3/9 3 69 (35.0)

CT3/10 3 99 (50.0)

CT3/11 3 138 (70.0)

CT3/12 3 188 (95.0)

CT3/13 3 237 (120.0)

CT3/14 3 296 (150.0)

CT3/15 3 365 (185.0)

CT3/16 3 474 (240.0)

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4.15.4 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 3

REF : CT4

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : Single Core STR CU/EPR/CSP/PBWB/CSP

Multicore STR CU/EPR/CSP/GSWB/CSP

USE : Power Distribution and Control, non fire survival where

increased oil resistance and flexibility are required (excluding
contiuous manned areas).

JACKET (SHEATH) : Black preferred.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.
Cores - Single colour coded insulation to NEMA WC3/WC57 (BS
6883) or printed numbers for 1, 2, 3 and 4 core cables (Section
4.4).
Colour coded insulation, Red, Black, Green/Yellow for 3 core
cables in single phase applications preferred.
White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded tinned annealed copper conductors.

Ethylene Propylene Rubber Insulation.
Chlorosulphonated Polyethylene bedding to NEMA WC3 (BS
6883 Type B).
Single core - Phosphor Bronze Wire Braid Armour.
Multicore - Galvanised Steel Wire Braid Armour.
Chlorosulphonated Polyethylene Jacket (oversheath) to
NEMA WC3 (BS 6883 Type B).

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature ≥ 482°F (250°C).
PROPERTIES HCl Emission ≤ 5% by weight of compound at
1472°F (800°C).
NEMA WC3 Part 6 (IEC 332 - Part 3 Category A, Reduced
Propagation).

STANDARDS & : USA - NEMA WC3/WC57/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6883 - Elastomer insulated cables for fixed
wiring in ships and on mobile and fixed offshore units.
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4.15.4 (Cont/d) Page 2 of 3

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT4
MATERIAL NO. OF CORES CSA MATERIAL NO. NO. OF CSA

NO. k.c.mil(mm2) CORES k.c.mil/(mm2)

CT4/1 1 50 (25) CT4/33 3 31.6 (16.0)

CT4/2 1 99 (50) CT4/34 3 50 (25.0)

CT4/3 1 138 (70) CT4/35 3 69 (35.0)

CT4/4 1 188 (95) CT4/36 3 99 (50.0)

CT4/5 1 237 (120) CT4/37 3 138 (70.0)

CT4/6 1 296 (150) CT4/38 3 188 (95.0)

CT4/7 1 365 (185.0) CT4/39 3 237 (120.0)

CT4/8 1 474 (240.0) CT4/40 3 296 (150.0)

CT4/9 1 592 (300.0) CT4/41 3 365 (185.0)

CT4/10 1 790 (400.0) CT4/42 3 474 (240.0)

CT4/11 1 987 (500.0) CT4/43 3 592 (300.0)

CT4/12 1 1244 (630.0) CT4/44 4 2.96 (1.5)

CT4/13 2 2.96 (1.5) CT4/45 4 4.9 (2.5)

CT4/14 2 4.9 (2.5) CT4/46 4 7.9 (4.0)

CT4/15 2 7.9 (4.0) CT4/47 4 11.8 (6.0)

CT4/16 2 11.8 (6.0) CT4/48 4 19.7 (10.0)

CT4/17 2 19.7 (10.0) CT4/49 4 31.6 (16.0)

CT4/18 2 31.6 (16.0) CT4/50 4 50 (25.0)

CT4/19 2 50 (25.0) CT4/51 4 69 (35.0)

CT4/20 2 69 (35.0) CT4/52 4 99 (50.0)

CT4/21 2 99 (50.0) CT4/53 4 138 (70.0)

CT4/22 2 138 (70.0) CT4/54 4 188 (95.0)

CT4/23 2 188 (95.0) CT4/55 4 237 (120.0)

CT4/24 2 237 (120.0) CT4/56 4 296 (150.0)

CT4/25 2 296 (150.0) CT4/57 4 365 (185.0)

CT4/26 2 365 (185.0) CT4/58 4 474 (240.0)

CT4/27 2 474 (240.) CT4/59 7 2.96 (1.5)

CT4/28 3 2.96 (1.5) CT4/60 7 4.9 (2.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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CT4/29 3 4.9 (2.5) CT4/61 12 2.96 (1.5)

CT4/30 3 7.9 (4.0) CT4/62 12 4.9 (2.5)

CT4/31 3 11.8 (6.0) CT4/63 19 2.96 (1.5)

CT4/32 3 19.7 (10.0) CT4/64 19 4.9 (2.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.4 (Cont/d) Page 3 of 3
REF: CT4
MATERIAL NO. OF CORES CSA

NO. k.c.mil(mm2)

CT4/65 27 2.96 (1.5)

CT4/66 27 4.9 (2.5)

IDENTIFICATION: SINGLE PHASE APPLICATIONS

Cores - Red/Black/Green-Yellow

CT4/67 3 2.96 (1.5)

CT4/68 3 4.9 (2.5)

CT4/69 3 7.9 (4.0)

CT4/70 3 11.8 (6.0)

CT4/71 3 19.7 (10.0)

CT4/72 3 31.6 (16.0)

CT4/73 3 50 (25.0)

CT4/74 3 69 (35.0)

CT4/75 3 99 (50.0)

CT4/76 3 138 (70.0)

CT4/77 3 188 (95.0)

CT4/78 3 237 (120.0)

CT4/79 3 296 (150.0)

CT4/80 3 365 (185.0)

CT4/81 3 474 (240.0)

CT4/82 3 592 (300.0)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.5 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT5

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : Single Core STR CU/PVC/PVC/AWA/PVC

Multicore STR CU/PVC/PVC/SWA/PVC

USE : Power Distribution and Control general use (excluding

continuously manned areas).

JACKET (SHEATH) : Black preferred.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.

Cores - Colour coded insulation to NEMA WC5/WC57 (BS 6346) or

printed numbers for 1,2,3 and 4 core cables.
Colour coded insulation, Red, Black, Green/Yellow for 3 core
cables in single phase applications preferred.
White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded plain copper conductors.

Polyvinyl Chloride insulation.
Polyvinyl Chloride bedding.
Single core - Aluminium Wire Armour.
Multicore - Galvanised Steel Wire Armour.
Polyvinyl Chloride Jacket (oversheath).

FIRE : Oxygen Index ≥ 30.

PERFORMANCE Temperature ≥ 572°F (300°C).
PROPERTIES HCl Emission ≤ 17% by weight of compound at
1472°F (800°C).
NEMA WC5 Part 6 (IEC 332 - Part 3 Category A, Reduced
Propagation).

STANDARDS & : USA - NEMA WC5/WC57/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
BS 6746 - for PVC insulation, type TI 1, and hard PVC sheath type TM 1.
BS 6346 - for construction, dimensions and tests.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.5 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT5
MATERIAL NO. OF CORES CSA MATERIAL NO. NO. OF CORES CSA

NO. k.c.mil(mm2) k.c.mil/(mm2)

CT5/1 1 50 (25.0) CT5/34 3 237 (120.0)

CT5/2 1 99 (50.0) CT5/35 3 296 (150.0)

CT5/3 1 138 (70.0) CT5/36 4 2.96 (1.5)

CT5/4 1 188 (95.0) CT5/37 4 4.9 (2.5)

CT5/5 1 237 (120.0) CT5/38 4 7.9 (4.0)

CT5/6 1 296 (150.0) CT5/39 4 11.8 (6.0)

CT5/7 1 365 (185.0) CT5/40 4 19.7 (10.0)

CT5/8 1 474 (240.0) CT5/41 4 31.6 (16.0)

CT5/9 1 592 (300.0) CT5/42 4 50 (25.0)

CT5/10 1 790 (400.0) CT5/43 4 69 (35.0)

CT5/11 1 987 (500.0) CT5/44 4 99 (50.0)

CT5/12 1 1244 (630.0) CT5/45 4 138 (70.0)

CT5/13 2 2.96 (1.5) CT5/46 4 188 (95.0)

CT5/14 2 4.9 (2.5) CT5/47 4 237 (120.0)

CT5/15 2 7.9 (4.0) CT5/48 4 296 (150.0)

CT5/16 2 11.8 (6.0) CT5/49 4 365 (185.0)

CT5/17 2 19.7 (10.0) CT5/50 7 2.96 (1.5)

CT5/18 2 31.6 (16.0) CT5/51 7 4.9 (2.5)

CT5/19 2 50 (25.0) CT5/52 12 2.96 (1.5)

CT5/20 2 69 (35.0) CT5/53 12 4.9 (2.5)

CT5/21 2 99 (50.0) CT5/54 19 2.96 (1.5)

CT5/22 2 138 (70.0) CT5/55 19 4.9 (2.5)

CT5/23 3 2.96 (1.5) CT5/56 27 2.96 (1.5)

CT5/24 3 4.9 (2.5) CT5/57 27 4.9 (2.5)

CT5/25 3 7.9 (4.0) IDENTIFICATION: SINGLE PHASE APPLICATIONS

Cores - Red/Black/Green-Yellow

CT5/26 3 11.8 (6.0) CT5/58 3 2.96 (1.5)

CT5/27 3 19.7 (10.0) CT5/59 3 4.9 (2.5)

CT5/28 3 31.6 (16.0) CT5/60 3 7.9 (4.0)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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CT5/29 3 50 (25.0) CT5/61 3 11.8 (6.0)

CT5/30 3 69 (35.0) CT5/62 3 19.7 (10.0)

CT5/31 3 99 (50.0) CT5/63 3 31.6 (16.0)

CT5/32 3 138 (70.0) CT5/64 3 50 (25.0)

CT5/33 3 188 (95.0) CT5/65 3 69 (35.0)

4.15.6 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT6

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : Single Core STR CU/XLPE/PVC/AWA/PVC

Multicore STR CU/XLPE/PVC/SWA/PVC

USE : Power Distribution and Control general use (excluding

continuously manned areas).

JACKET (SHEATH) : Black preferred.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.

Cores - Colour coded insulation to NEMA WC5/WC57 (BS 6346) or

printed numbers for 1,2,3 and 4 core cables.
Colour coded insulation, Red, Black, Green/Yellow for 3 core
cables in single phase applications preferred.
White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded plain copper conductors.

Cross-linked Polyethylene insulation.
Polyvinyl Chloride bedding.
Single core - Aluminium Wire Armour.
Multicore - Galvanised Steel Wire Armour.
Polyvinyl Chloride Jacket (oversheath).

FIRE : Oxygen Index ≥ 30.

PERFORMANCE Temperature ≥ 572°F (300°C).
PROPERTIES HCl Emission ≤ 17% by weight of compound at
1472°F (800°C).
NEMA WC5 Part 6 (IEC 332 - Part 3 Category A, Reduced
Propagation).

STANDARDS & : USA - NEMA WC5/WC57/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
BS/IEC - BS 5467 - for construction, dimensions and tests.
BS/IEC - IEC 502 - for construction, dimensions and tests.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999

4.15.6 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT6
MATERIAL NO. OF CORES CSA MATERIAL NO NO. OF CSA

NO. k.c.mil(mm2) CORES k.c.mil/(mm2)

CT6/1 1 50 (25.0) CT6/34 3 237 (120.0)

CT6/2 1 99 (50.0) CT6/35 3 296 (150.0)

CT6/3 1 138 (70.0) CT6/36 4 2.96 (1.5)

CT6/4 1 188 (95.0) CT6/37 4 4.9 (2.5)

CT6/5 1 237 (120.0) CT6/38 4 7.9 (4.0)

CT6/6 1 296 (150.0) CT6/39 4 11.8 (6.0)

CT6/7 1 365 (185.0) CT6/40 4 19.7 (10.0)

CT6/8 1 474 (240.0) CT6/41 4 31.6 (16.0)

CT6/9 1 592 (300.0) CT6/42 4 50 (25.0)

CT6/10 1 790 (400.0) CT6/43 4 69 (35.0)

CT6/11 1 987 (500.0) CT6/44 4 99 (50.0)

CT6/12 1 1244 (630.0) CT6/45 4 138 (70.0)

CT6/13 2 2.96 (1.5) CT6/46 4 188 (95.0)

CT6/14 2 4.9 (2.5) CT6/47 4 237 (120.0)

CT6/15 2 7.9 (4.0) CT6/48 4 296 (150.0)

CT6/16 2 11.8 (6.0) CT6/49 4 365 (185.0)

CT6/17 2 19.7 (10.0) CT6/50 7 2.96 (1.5)

CT6/18 2 31.6 (16.0) CT6/51 7 4.9 (2.5)

CT6/19 2 50 (25.0) CT6/52 12 2.96 (1.5)

CT6/20 2 69 (35.0) CT6/53 12 4.9 (2.5)

CT6/21 2 99 (50.0) CT6/54 19 2.96 (1.5)

CT6/22 2 138 (70.0) CT6/55 19 4.9 (2.5)

CT6/23 3 2.96 (1.5) CT6/56 27 2.96 (1.5)

CT6/24 3 4.9 (2.5) CT6/57 27 4.9 (2.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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CT6/25 3 7.9 (4.0) IDENTIFICATION: SINGLE PHASE APPLICATIONS

Cores - Red/Black/Green-Yellow

CT6/26 3 11.8 (6.0) CT6/58 3 2.96 (1.5)

CT6/27 3 19.7 (10.0) CT6/59 3 4.9 (2.5)

CT6/28 3 31.6 (16.0) CT6/60 3 7.9 (4.0)

CT6/29 3 50 (25.0) CT6/61 3 11.8 (6.0)

CT6/30 3 69 (35.0) CT6/62 3 19.7 (10.0)

CT6/31 3 99 (50.0) CT6/63 3 31.6 (16.0)

CT6/32 3 138 (70.0) CT6/64 3 50 (25.0)

CT6/33 3 188 (95.0) CT6/65 3 69 (35.0)

4.15.7 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT7

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : Single Core STR CU/MT/EPR/EPDM/PBWB/CSP

Multicore STR CU/MT/EPR/EPDM/GSWB/CSP

USE : Power Distribution and Control for use in Fire Survival

Applications (excluding continuously manned areas).

JACKET (SHEATH) : Black preferred.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.

Cores - Colour coded insulation to NEMA WC3/WC57 (BS 6883) or

printed numbers for 1,2,3 and 4 core cables.
- Colour coded insulation, Red, Black, Green/Yellow for 3 core
cables in single phase applications preferred.
- White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded tinned annealed copper conductors.

Mica-glass tape.
Ethylene Propylene Rubber insulation.
Ethylene Propylene Diene Monomer bedding or equal.
Single core - Phosphor Bronze Wire Braid Armour.
Multicore - Galvanised Steel Wire Braid Armour
Chlorosulphonated Polyethylene Jacket (oversheath).

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature ≥ 482°F (250°C).
PROPERTIES HCl Emission ≤ 5% by weight of compound at 1472°F
(800°C).
NEMA WC3 Part 6 (IEC 331 - Enhanced to 1832°F (1000°C),
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
3 hr's Fire Resistance).
IEC 332 - Part 3, Category A, Reduced Propagation.

STANDARDS & : USA - NEMA WC3/WC57/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
BS 6899 - for EPR insulation type GP 4 and HOFR CSP
sheath, type RS 3 or RS 4.
BS 6883 - for construction, dimensions and tests.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.7 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT7
MATERIAL NO. NO. OF CSA MATERIAL NO NO. OF CSA

CORES k.c.mil(mm2) CORES k.c.mil/(mm2)

CT7/1 1 50 (25.0) CT7/33 3 188 (95.0)

CT7/2 1 99 (50.0) CT7/34 3 237 (120.0)

CT7/3 1 138 (70.0) CT7/35 3 296 (150.0)

CT7/4 1 188 (95.0) CT7/36 3 365 (185.0)

CT7/5 1 237 (120.0) CT7/37 4 2.96 (1.5)

CT7/6 1 296 (150.0) CT7/38 4 4.9 (2.5)

CT7/7 1 365 (185.0) CT7/39 4 7.9 (4.0)

CT7/8 1 474 (240.0) CT7/40 4 11.8 (6.0)

CT7/9 1 592 (300.0) CT7/41 4 19.7 (10.0)

CT7/10 2 2.96 (1.5) CT7/42 4 31.6 (16.0)

CT7/11 2 4.9 (2.5) CT7/43 4 50 (25.0)

CT7/12 2 7.9 (4.0) CT7/44 4 69 (35.0)

CT7/13 2 11.8 (6.0) CT7/45 4 99 (50.0)

CT7/14 2 19.7 (10.0) CT7/46 4 138 (70.0)

CT7/15 2 31.6 (16.0) CT7/47 7 2.96 (1.5)

CT7/16 2 50 (25.0) CT7/48 7 4.9 (2.5)

CT7/17 2 69 (35.0) CT7/49 12 2.96 (1.5)

CT7/18 2 99 (50.0) CT7/50 12 4.9 (2.5)

CT7/19 2 138 (70.0) CT7/51 19 2.96 (1.5)

CT7/20 2 188 (95.0) CT7/52 19 4.9 (2.5)

CT7/21 2 237 (120.0) CT7/53 27 2.96 (1.5)

CT7/22 2 296 (150.0) CT7/54 27 4.9 (2.5)

CT7/23 3 2.96 (1.5) IDENTIFICATION: SINGLE PHASE APPLICATIONS

Cores - Red/Black/Green-Yellow

CT7/24 3 4.9 (2.5) CT7/55 3 2.96 (1.5)

CT7/25 3 7.9 (4.0) CT7/56 3 4.9 (2.5)

CT7/26 3 11.8 (6.0) CT7/57 3 7.9 (4.0)

CT7/27 3 19.7 (10.0) CT7/58 3 11.8 (6.0)

CT7/28 3 31.6 (16.0) CT7/59 3 19.7 (10.0)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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CT7/29 3 50 (25.0) CT7/60 3 31.6 (16.0)

CT7/30 3 69 (35.0) CT7/61 3 50 (25.0)

CT7/31 3 99 (50.0) CT7/62 3 69 (35.0)

CT7/32 3 138 (70.0)

4.15.8 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 1

REF : CT8

TYPE : LV, 750 V (Heavy Duty) Grade MICC

ABBREVIATION : SOL CU/MI/CU-SHEATH

USE : Small Power Distribution for use in Fire Survival applications

in continuously manned areas and buildings.

JACKET (SHEATH) : Bare.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Bare copper (not applicable).

Cores - Bare copper (sleeved and identified at termination by
installation contractor).

CONSTRUCTION : Solid plain copper conductors.

Mineral insulated, moisture proof insulant preferred.
Solid drawn or seam welded copper sheath.

FIRE : ANSI/NFPA 262-1990 (IEC 331 - enhanced to 1832°F

PERFORMANCE (1000°C), 3hr's Fire Resistance).
PROPERTIES

STANDARDS & : USA - NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
IEC 702 (BS 6207) - for construction, dimensions and tests.

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

MATERIAL NO. NO. OF CSA

CORES k.c.mil(mm2)

CT8/1 2 2.96 (1.5)

CT8/2 2 4.9 (2.5)

CT8/3 2 7.9 (4.0)

CT8/4 3 2.96 (1.5)

CT8/5 3 4.9 (2.5)

CT8/6 3 7.9 (4.0)

CT8/7 4 2.96 (1.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
CT8/8 4 4.9 (2.5)

CT8/9 4 7.9 (4.0)

4.15.9 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT9

TYPE : LV, 750 V (Heavy Duty) Grade MICC

ABBREVIATION : SOL CU/MI/CU-SHEATH/EVA

USE : Small Power Distribution, I.S., non I.S., Instrument and Fire
and Gas cables for use in Fire Survival application in
continuously manned areas and buildings.

JACKET (SHEATH) : White/self coloured preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Bare copper (sleeved and identified at termination by

installation contractor).

CONSTRUCTION : Solid plain copper conductors.

Mineral insulated, moisture proof insulant preferred.
Solid drawn or seam welded copper sheath.
Ethylene Vinyl Acetate jacket (oversheath).

FIRE Oxygen Index ≥ 30.

PERFORMANCE : Temperature ≥ 500°F (260°C).
PROPERTIES HCl Emission ≤ 0/5% by weight of compound at
1472°F (800°C).
Low smoke low halogen (LSLH) properties.
ANSI/NFPA 262-1990 (IEC 331 - enhanced to 1832°F
(1000°C), 3 hr's Fire Resistance).
ANSI/NFPA 262-1990 (IEC 332 - Part 3, Category A,
Reduced Propagation).

STANDARDS & : USA - NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS6360 - for solid copper conductors.
BS/IEC - IEC 702 (BS 6207) - for construction, dimensions
and tests.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.9 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT9
MATERIAL NO. NO. OF CSA

CORES k.c.mil(mm2)

CT9/1 2 2.96 (1.5)

CT9/2 2 4.9 (2.5)

CT9/3 2 7.9 (4.0)

CT9/4 3 2.96 (1.5)

CT9/5 3 4.9 (2.5)

CT9/6 3 7.9 (4.0)

CT9/7 4 2.96 (1.5)

CT9/8 4 4.9 (2.5)

CT9/9 4 7.9 (4.0)

CT9/10 7 2.96 (1.5)

CT9/11 7 4.9 (2.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.10 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 3

REF : CT10

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : Single Core STR CU/EPR/NBR.PVC/PBWB/NBR.PVC

Multicore STR CU/EPR/NBR.PVC/GSWB/NBR.PVC

USE : Power Distribution and Control in areas particularly liable to

contamination from oil.
JACKET (SHEATH)
COLOUR : Black preferred.

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Colour coded insulation to NEMA WC3/WC57 (BS 6883) or

printed numbers for 1,2,3 and 4 core cables.
- Colour coded insulation, Red, Black, Green/Yellow for 3 core
cables in single phase applications preferred.
- White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded metal coated copper conductors.

Ethylene Propylene Rubber insulation.
Nitrile Butadiene Rubber/Polyvinyl Chloride (or equal)
bedding.
Single core - Phosphor Bronze Wire Braid Armour.
Multicore - Galvanised Steel Wire Braid Armour.
Nitrile Butadiene Rubber/Polyvinyl Chloride (or equal) jacket
(oversheath).

FIRE : Oxygen Index ≥ 26.

PERFORMANCE Temperature ≥ 482°F (250°C).
PROPERTIES NEMA WC3 Part 6 HCl Emission 13% by weight of
compound at 1472°F (800°C).
NEMA WC3 Part 6 (IEC 332 - Part 3, Category A, Reduced
Propagation).

STANDARDS & : USA - WC3/WC57/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS6360 - for solid copper conductors.
BS 6899 - for EPR insulation type GP 1 or GP 2 and
NBR.PVC Jacket (sheath) (or equal), equivalent to type RS 3
or RS 4 with HOFR properties equal or superior to NIPLAS
915.
BS 6883 - for construction, dimensions and tests.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.10 (Cont/d) Page 2 of 3

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT10
MATERIAL NO. OF CSA MATERIAL NO NO. OF CSA

NO. CORES k.c.mil(mm2) CORES k.c.mil/(mm2)

CT10/1 1 99 (50.0) CT10/33 3 50 (25.0)

CT10/2 1 138 (70.0) CT10/34 3 69 (35.0)

CT10/3 1 188 (95.0) CT10/35 3 99 (50.0)

CT10/4 1 237 (120.0) CT10/36 3 138 (70.0)

CT10/5 1 296 (150.0) CT10/37 3 188 (95.0)

CT10/6 1 365 (185.0) CT10/38 3 237 (120.0)

CT10/7 1 474 (240.0) CT10/39 3 296 (150.0)

CT10/8 1 592 (300.0) CT10/40 3 365 (185.0)

CT10/9 1 790 (400.0) CT10/41 3 474 (240.0)

CT10/10 1 987 (500.0) CT10/42 3 592 (300.0)

CT10/11 1 1244 (630.0) CT10/43 4 2.96 (1.5)

CT10/12 2 2.96 (1.5) CT10/44 4 4.9 (2.5)

CT10/13 2 4.9 (2.5) CT10/45 4 7.9 (4.0)

CT10/14 2 7.9 (4.0) CT10/46 4 11.8 (6.0)

CT10/15 2 11.8 (6.0) CT10/47 4 19.7 (10.0)

CT10/16 2 19.7 (10.0) CT10/48 4 31.6 (16.0)

CT10/17 2 31.6 (16.0) CT10/49 4 50 (25.0)

CT10/18 2 50 (25.0) CT10/50 4 69 (35.0)

CT10/19 2 69 (35.0) CT10/51 4 99 (50.0)

CT10/20 2 99 (50.0) CT10/52 4 138 (70.0)

CT10/21 2 138 (70.0) CT10/53 4 188 (95.0)

CT10/22 2 188 (95.0) CT10/54 4 237 (120.0)

CT10/23 2 237 (120.0) CT10/55 4 296 (150.0)

CT10/24 2 296 (150.0) CT10/56 4 365 (185.0)

CT10/25 2 365 (185.0) CT10/57 4 474 (240.0)

CT10/26 2 474 (240.0) CT10/58 7 2.96 (1.5)

CT10/27 3 2.96 (1.5) CT10/59 7 4.9 (2.5)

CT10/28 3 4.9 (2.5) CT10/60 12 2.96 (1.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
CT10/29 3 7.9 (4.0) CT10/61 12 4.9 (2.5)

CT10/30 3 11.8 (6.0) CT10/62 19 2.96 (1.5)

CT10/31 3 19.7 (10.0) CT10/63 19 4.9 (2.5)

CT10/32 3 31.6 (16.0)

 GENERAL ENGINEERING SPECIFICATION GES L.02
POWER AND CONTROL CABLES Page 48 of 74
Rev 0 1999
4.15.10 (Cont/d) Page 3 of 3
REF: CT10
MATERIAL NO. OF CSA

NO. CORES k.c.mil(mm2)

CT10/64 27 2.96 (1.5)

CT10/65 27 4.9 (2.5)

IDENTIFICATION: SINGLE PHASE APPLICATIONS

Cores - Red/Black/Green-Yellow

CT10/66 3 2.96 (1.5)

CT10/67 3 4.9 (2.5)

CT10/68 3 7.9 (4.0)

CT10/69 3 11.8 (6.0)

CT10/70 3 19.7 (10.0)

CT10/71 3 31.6 (16.0)

CT10/72 3 50 (25.0)

CT10/73 3 69 (35.0)

CT10/74 3 99 (50.0)

CT10/75 3 138 (70.0)

CT10/76 3 188 (95.0)

CT10/77 3 237 (120.0)

CT10/78 3 296 (150.0)

CT10/79 3 365 (185.0)

CT10/80 3 474 (240.0)

CT10/81 3 592 (300.0)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.11 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 3

REF : CT11

TYPE : LV, 0.45/0.75 kV Grade, Flexible

ABBREVIATION : Single Core FLEX CU/EPR/NBR.PVC/PBWB/NBR.PVC

Multicore FLEX CU/EPR/NBR.PVC/GSWB/NBR.PVC

USE : Power Distribution and Control in areas particularly liable to

contamination from oil application in continuously manned
areas.

JACKET (SHEATH) : Black preferred.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Colour coded insulation to NEMA WC3 (BS 6883) or printed

numbers for 1,2,3 and 4 core cables.
- Colour coded insulation, Red, Black, Green/Yellow for 3 core
cables in single phase applications preferred.
- White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Flexible metal coated copper conductors.

Ethylene Propylene Rubber insulation.
Nitrile Butadiene Rubber/Polyvinyl Chloride (or equal)
bedding.
Single core - Phosphor Bronze Wire Braid Armour.
Multicore - Galvanised Steel Wire Braid Armour.
Nitrile Butadiene Rubber/Polyvinyl Chloride (or equal) Jacket
(oversheath).

FIRE : Oxygen Index ≥ 26.

PERFORMANCE Temperature ≥ 482°F (250°C).
PROPERTIES NEMA WC3 Part 6 HCl Emission ≤ 13% by weight of
compound at 1472°F (800°C).
NEMA WC3 Part 6 (IEC 332 - Part 3 Category A, Reduced
Propagation).

STANDARDS & : USA - WC3/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for flexible copper conductors, class 5.
BS 6899 - for EPR insulation, type GP 1 or GP 2 and
NBR.PVC sheath (or equal) equivalent to type RS 3 or RS 4
with HOFR properties equal or superior to NIPLAS 915.
BS 6883 - for construction, dimensions and tests.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.11 (Cont/d) Page 2 of 3

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT9
MATERIAL NO. OF CSA MATERIAL NO NO. OF CSA

NO. CORES k.c.mil(mm2) CORES k.c.mil/(mm2)

CT11/1 1 99 (50.0) CT11/33 3 50 (25.0)

CT11/2 1 138 (70.0) CT11/34 3 69 (35.0)

CT11/3 1 188 (95.0) CT11/35 3 99 (50.0)

CT11/4 1 237 (120.0) CT11/36 3 138 (70.0)

CT11/5 1 296 (150.0) CT11/37 3 188 (95.0)

CT11/6 1 365 (185.0) CT11/38 3 237 (120.0)

CT11/7 1 474 (240.0) CT11/39 3 296 (150.0)

CT11/8 1 592 (300.0) CT11/40 3 365 (185.0)

CT11/9 1 790 (400.0) CT11/41 3 474 (240.0)

CT11/10 1 987 (500.0) CT11/42 3 592 (300.0)

CT11/11 1 1244 (630.0) CT11/43 4 2.96 (1.5)

CT11/12 2 2.96 (1.5) CT11/44 4 4.9 (2.5)

CT11/13 2 4.9 (2.5) CT11/45 4 7.9 (4.0)

CT11/14 2 7.9 (4.0) CT11/46 4 11.8 (6.0)

CT11/15 2 11.8 (6.0) CT11/47 4 19.7 (10.0)

CT11/16 2 19.7 (10.0) CT11/48 4 31.6 (16.0)

CT11/17 2 31.6 (16.0) CT11/49 4 50 (25.0)

CT11/18 2 50 (25.0) CT11/50 4 69 (35.0)

CT11/19 2 69 (35.0) CT11/51 4 99 (50.0)

CT11/20 2 99 (50.0) CT11/52 4 138 (70.0)

CT11/21 2 138 (70.0) CT11/53 4 188 (95.0)

CT11/22 2 188 (95.0) CT11/54 4 237 (120.0)

CT11/23 2 237 (120.0) CT11/55 4 296 (150.0)

CT11/24 2 296 (150.0) CT11/56 4 365 (185.0)

CT11/25 2 365 (185.0) CT11/57 4 474 (240.0)

CT11/26 2 474 (240.0) CT11/58 7 2.96 (1.5)

CT11/27 3 2.96 (1.5) CT11/59 7 4.9 (2.5)

CT11/28 3 4.9 (2.5) CT11/60 12 2.96 (1.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
CT11/29 3 7.9 (4.0) CT11/61 12 4.9 (2.5)

CT11/30 3 11.8 (6.0) CT11/62 19 2.96 (1.5)

CT11/31 3 19.7 (10.0) CT11/63 19 4.9 (2.5)

CT11/32 3 31.6 (16.0)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.11 (Cont/d) Page 3 of 3
REF: CT11
MATERIAL NO. OF CSA

NO. CORES k.c.mil(mm2)

IDENTIFICATION: SINGLE PHASE APPLICATIONS

Cores - Red/Black/Green-Yellow

CT11/64 3 2.96 (1.5)

CT11/65 3 4.9 (2.5)

CT11/66 3 7.9 (4.0)

CT11/67 3 11.8 (6.0)

CT11/68 3 19.7 (10.0)

CT11/69 3 31.6 (16.0)

CT11/70 3 50 (25.0)

CT11/71 3 69 (35.0)

CT11/72 3 99 (50.0)

CT11/73 3 138 (70.0)

CT11/74 3 188 (95.0)

CT11/75 3 237 (120.0)

CT11/76 3 296 (150.0)

CT11/77 3 365 (185.0)

CT11/78 3 474 (240.0)

CT11/79 3 592 (300.0)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.12 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 1

REF : CT12

TYPE : LV, 0.6/1.0 kV Grade, Flexible

ABBREVIATION : FLEX CU/EPR/CSP

USE : Battery Terminal Interconnections.

JACKET (SHEATH) : Black preferred, self colour acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Ferrules (Tags) attached by Installation Contractor.

CONSTRUCTION : Flexible tinned annealed copper conductors.

Ethylene Propylene Rubber insulation.
Chlorosulphonated Polyethylene Jacket (oversheath).

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature ≥ 482°F (250°C).
PROPERTIES NEMA WC3 Part 6 HCl Emission ≤ 5% by weight of
compound at 1472°F (800°C).
NEMA WC3 Part 6 (IEC 332 - Part 1, Flame Test, Single
Vertical Cable).

STANDARDS & : USA - NEMA WC3/NFPA70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for flexible copper conductors, Class 5.
BS 6899 - for insulation type FR 1.
BS 6195 - Type 4C, for construction, dimensions and tests.

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

MATERIAL NO. NO. OF CSA

CORES k.c.mil(mm2)

CT12/1 1 31.6 (16)

CT12/2 1 50 (25)

CT12/3 1 99 (50)

CT12/4 1 237 (120)

CT12/5 1 474 (240)

CT12/6 1 790 (400)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.13 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT13

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : STR CU/POLYRAD XT/PBWB/POLYRAD XT

USE : Cathodic Protection general use on surface and underwater.

JACKET (SHEATH) : Black preferred.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Ferrules (Tags) attached by Installation Contractor.

CONSTRUCTION : Stranded metal coated copper conductors.

POLYRAD XT (or equal) insulation.
Phosphor Bronze Wire Braided Armour.
POLYRAD XT (or equal) jacket (oversheath).

FIRE Oxygen Index ≥ 29.

PERFORMANCE : Temperature index ≥ 500°F (260°C).
PROPERTIES HCl Emission ≤ 5% by weight of compound at
1472°F (800°C).
Toxicity Index 5.7 (NES 713).
Smoke Index 53 (NES 711).
ANSI/NFPA 262 (1990) (IEC 332 - Part 1, Flame Test, Single
Vertical Cable).
ANSI/NFPA 262 (1990) (IEC 332 - Part 3, Category A,
Reduced Propagation).

STANDARDS & : USA - NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.13 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT13
MATERIAL NO. NO. OF CSA

CORES k.c.mil(mm2)

CT13/1 1 2.96 (1.5)

CT13/2 1 4.9 (2.5)

CT13/3 1 7.9 (4.0)

CT13/4 1 11.8 (6.0)

CT13/5 1 19.7 (10.0)

CT13/6 1 31.6 (16.0)

CT13/7 1 50 (25.0)

CT13/8 1 99 (50.0)
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.14 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT14

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : STR CU/EPR/CSP

USE : Earthing where increased flexibility and oil resistance are

required.

JACKET (SHEATH) : Green or yellow strip.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Ferrules (Tags) attached by Installation Contractor (if

required).

CONSTRUCTION : Stranded metal coated copper conductors.

Ethylene Propylene Rubber insulation.
Chlorosulphonated Polyethylene oversheath.

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature index ≥ 482°F (250°C).
PROPERTIES NEMA WC3 Part 6 HCl emission ≤ 5% by weight of
compound at 1472°F (800°C).
NEMA WC3 Part 6 (IEC 332 - Part 1, Flame Test, Single
Vertical Cable).

STANDARDS & : USA - NEMA WC3/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
BS 6899 - for EPR insulation, type GP 4 and HOFR CSP
sheath, type RS 3.
BS 6883 - for construction, dimensions and tests.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.14 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT14
MATERIAL NO. NO. OF CSA MATERIAL NO. NO. OF CSA

CORES k.c.mil(mm2) CORES k.c.mil (mm2)

CT14/1 1 2.96 (1.5) CT14/8 1 69 (35.0)

CT14/2 1 4.9 (2.5) CT14/9 1 99 (50.0)

CT14/3 1 7.9 (4.0) CT14/10 1 138 (70.0)

CT14/4 1 11.8 (6.0) CT14/11 1 188 (95.0)

CT14/5 1 19.7 (10.0) CT14/12 1 237 (120.0)

CT14/6 1 31.6 (16.0) CT14/13 1 296 (150.0)

CT14/7 1 50 (25.0)
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.15 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 1

REF : CT15

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : STR CU/PVC

USE : Earthing general use.

JACKET (SHEATH) : Green and Yellow Strip.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Ferrules (Tags) attached by Installation Contractor (if

required).

CONSTRUCTION : Stranded plain copper conductors.

Polyvinyl Chloride insulation.

FIRE : Oxygen Index ≥ 30.

PERFORMANCE Temperature index ≥ 572°F (300°C).
PROPERTIES NEMA/WC5 Part 6 HCl emission ≤ 17% by weight of
compound at 1472°F (800°C).
NEMA WC5 Part 6 (IEC 332 - Part 1, Flame Test, Single
Vertical Cable).

STANDARDS & : USA - NEMA WC5/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors, class 2.
BS 6746 - for PVC insulation, type TI 1.
BS 6231 - for construction, dimensions and tests.

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

MATERIAL NO. NO. OF CSA MATERIAL NO. NO. OF CSA

CORES k.c.mil(mm2) CORES k.c.mil (mm2)

CT15/1 1 2.96 (1.5) CT15/8 1 69 (35.0)

CT15/2 1 4.9 (2.5) CT15/9 1 99 (50.0)

CT15/3 1 7.9 (4.0) CT15/10 1 138 (70.0)

CT15/4 1 11.8 (6.0) CT15/11 1 188 (95.0)

CT15/5 1 19.7 (10.0) CT15/12 1 237 (120.0)

CT15/6 1 31.6 (16.0) CT15/13 1 296 (150.0)

CT15/7 1 50 (25.0)
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999

4.15.16 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 3

REF : CT16

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : Single Core STR CU/EPR/EVA/PBWB/EVA

Multicore STR CU/EPR/EVA/GSWB/EVA

USE : Power Distribution and Control, General non fire survival use
in continuously manned areas.

JACKET (SHEATH) : White/self coloured preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Colour coded insulation to NEMA WC3/WC57 (BS 6883) or

printed numbers for 1, 2, 3 and 4 core cables.

- Colour coded insulation with Red, Black, Green/Yellow for 3

core cables in single phase applications preferred.

- White insulation and black printed numbers at ≤ 75 mm

intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded tinned annealed copper conductors.

Ethylene Propylene Rubber Insulation.
Thermoplastic EVA bedding.
Single core - Phosphor Bronze Wire Braid Armour.
Multicore - Galvanised Steel Wire Braid Armour.
Thermoplastic EVA Sheath.

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature Index > 500°F (260°C).
PROPERTIES HCl Emission ≤ 0.5% by weight of compound at
1472°F (800°C).
Low Smoke Low Halogen (LSLH) properties.
NEMA WC3 Part 6 (IEC 332 - Part 3, Category A, Reduced
Propagation).

STANDARDS & : USA - NEMA WC3/WC57/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors, class 2.
BS 6899 for EPR Insulation Type GP 4.
BS 6724 for Thermoplastic EVA Bedding and Sheath.
BS 6883 for Construction and Dimensions.
 GENERAL ENGINEERING SPECIFICATION GES L.02
POWER AND CONTROL CABLES Page 60 of 74
Rev 0 1999
4.15.16 (Cont/d) Page 2 of 3

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT16
MATERIAL NO. OF CSA MATERIAL NO NO. OF CSA

NO. CORES k.c.mil(mm2) CORES k.c.mil/(mm2)

CT16/1 1 50 (25.0) CT16/34 3 69 (35.0)

CT16/2 1 69 (35.0) CT16/35 3 99 (50.0)

CT16/3 1 99 (50.0) CT16/36 3 138 (70.0)

CT16/4 1 138 (70.0) CT16/37 3 188 (95.0)

CT16/5 1 188 (95.0) CT16/38 3 237 (120.0)

CT16/6 1 237 (120.0) CT16/39 3 296 (150.0)

CT16/7 1 296 (150.0) CT16/40 3 365 (185.0)

CT16/8 1 365 (185.0) CT16/41 3 474 (240.0)

CT16/9 1 474 (240.0) CT16/42 3 592 (300.0)

CT16/10 1 592 (300.0) CT16/43 4 2.96 (1.5)

CT16/11 1 790 (400.0) CT16/44 4 4.9 (2.5)

CT16/12 1 987 (500.0) CT16/45 4 7.9 (4.0)

CT16/13 1 1244 (630.0) CT16/46 4 11.8 (6.0)

CT16/14 2 2.96 (1.5) CT16/47 4 19.7 (10.0)

CT16/15 2 4.9 (2.5) CT16/48 4 31.6 (16.0)

CT16/16 2 7.9 (4.0) CT16/49 4 50 (25.0)

CT16/17 2 11.8 (6.0) CT16/50 4 69 (35.0)

CT16/18 2 19.7 (10.0) CT16/51 4 99 (50.0)

CT16/19 2 31.6 (16.0) CT16/52 4 138 (70.)

CT16/20 2 50 (25.0) CT16/53 4 188 (95.0)

CT16/21 2 69 (35.0) CT16/54 4 237 (120.0)

CT16/22 2 99 (50.0) CT16/55 4 296 (150.)

CT16/23 2 138 (70.0) CT16/56 4 365 (185.0)

CT16/24 2 188 (95.0) CT16/57 4 474 (240.0)

CT16/25 2 237 (120.) CT16/58 7 2.96 (1.5)

CT16/26 2 296 (150.0) CT16/59 7 4.9 (2.5)

CT16/27 3 2.96 (1.5) CT16/60 12 2.96 (1.5)

CT16/28 3 4.9 (2.5) CT16/61 12 4.9 (2.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
CT16/29 3 7.9 (4.0) CT16/62 19 2.96 (1.5)

CT16/30 3 11.8 (6.0) CT16/63 19 4.9 (2.5)

DT16/31 3 19.7 (10.0) CT16/64 27 2.96 (1.5)

CT16/32 3 31.6 (16.0) CT16/65 27 4.9 (2.5)

CT16/33 3 50 (25.0) - - -
 GENERAL ENGINEERING SPECIFICATION GES L.02
POWER AND CONTROL CABLES Page 62 of 74
Rev 0 1999
4.15.16 (Cont/d) Page 3 of 3
REF: CT16
MATERIAL NO. OF CSA

NO. CORES k.c.mil(mm2)

IDENTIFICATION: SINGLE PHASE APPLICATION

Cores - Red/Black/Green-Yellow

CT16/66 3 2.96 (1.5)

CT16/67 3 4.9 (2.5)

CT16/68 3 7.9 (4.0)

CT16/69 3 11.8 (6.0)

CT16/70 3 19.7 (10.0)

CT16/71 3 31.6 (16.0)

CT16/72 3 50 (25.0)

CT16/73 3 69 (35.0)
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.17 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 3

REF : CT17

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : Single Core STR CU/MT/EPR/EVA/PBWB/EVA

Multicore STR CU/MT/EPR/EVA/GSWB/EVA

USE : Power Distribution and Control General fire survival use in

continuously manned areas.

JACKET (SHEATH) : White/self coloured preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed, at ≤ 3 m intervals.

Cores - Colour coded insulation to NEMA WC3/WC57 (BS 6883) or

printed numbers for 1, 2, 3 and 4 core cables.
- Colour coded insulation with Red, Black, Green/Yellow for 3
core cables in single phase applications preferred.
- White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded tinned annealed copper conductors.

Mica-glass tape.
Ethylene Propylene Rubber Insulation.
Thermoplastic EVA bedding.
Single core - Phosphor Bronze Wire Braid Armour.
Multicore - Galvanised Steel Wire Braid Armour.
Thermoplastic EVA Sheath.

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature Index ≥ 482°F (250°C).
PROPERTIES HCl Emission ≤ 0.5% by weight of compound at
1472°F (800°C).
Low Smoke Low Halogen (LSLH) properties.
NEMA WC3 Part 6 (IEC 331 - Enhanced to 1832°F (1000°C),
3 hr's Fire Resistance).
NEMA WC3 Part 6 (IEC 332 - Part 3, Category A, Reduced
Propagation).

STANDARDS & : USA - NEMA WC3/WC57/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded copper conductors.
BS 6899 for EPR Insulation Type GP 4.
BS 6883 - for construction, dimensions.
BS 6724 - for Thermoplastic EVA bedding and sheath.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
4.15.17 (Cont/d) Page 2 of 3

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT17
MATERIAL NO. OF CSA MATERIAL NO NO. OF CSA

NO. CORES k.c.mil(mm2) CORES k.c.mil/(mm2)

CT17/1 1 50 (25.0) CT17/34 3 69 (35.0)

CT17/2 1 69 (35.0) CT17/35 3 99 (50.0)

CT17/3 1 99 (50.0) CT17/36 3 138 (70.0)

CT17/4 1 138 (70.0) CT17/37 3 188 (95.0)

CT17/5 1 188 (95.0) CT17/38 3 237 (120.0)

CT17/6 1 237 (120.0) CT17/39 3 296 (150.0)

CT17/7 1 296 (150.0) CT17/40 3 365 (185.0)

CT17/8 1 365 (185.0) CT17/41 3 474 (240.0)

CT17/9 1 474 (240.0) CT17/42 3 592 (300.0)

CT17/10 1 592 (300.0) CT17/43 4 2.96 (1.5)

CT17/11 1 790 (400.0) CT17/44 4 4.9 (2.5)

CT17/12 1 987 (500.0) CT17/45 4 7.9 (4.0)

CT17/13 1 1244 (630.0) CT17/46 4 11.8 (6.0)

CT17/14 2 2.96 (1.5) CT17/47 4 19.7 (10.0)

CT17/15 2 4.9 (2.5) CT17/48 4 31.6 (16.0)

CT17/16 2 7.9 (4.0) CT17/49 4 50 (25.0)

CT17/17 2 11.8 (6.0) CT17/50 4 69 (35.0)

CT17/18 2 19.7 (10.0) CT17/51 4 99 (50.0)

CT17/19 2 31.6 (16.0) CT17/52 4 138 (70.0)

CT17/20 2 50 (25.0) CT17/53 4 188 (95.0)

CT17/21 2 69 (35.0) CT17/54 4 237 (120.0)

CT17/22 2 99 (50.0) CT17/55 4 296 (150.)

CT17/23 2 138 (70.0) CT17/56 4 365 (185.0)

CT17/24 2 188 (95.0) CT17/57 4 474 (240.0)

CT17/25 2 237 (120.) CT17/58 7 2.96 (1.5)

CT17/26 2 296 (150.0) CT17/59 7 4.9 (2.5)

CT17/27 3 2.96 (1.5) CT17/60 12 2.96 (1.5)

CT17/28 3 4.9 (2.5) CT17/61 12 4.9 (2.5)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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CT17/29 3 7.9 (4.0) CT17/62 19 2.96 (1.5)

CT17/30 3 11.8 (6.0) CT17/63 19 4.9 (2.5)

DT17/31 3 19.7 (10.0) CT17/64 27 2.96 (1.5)

CT17/32 3 31.6 (16.0) CT17/65 27 4.9 (2.5)

CT17/33 3 50 (25.0) - - -

4.15.17 (Cont/d) Page 3 of 3

REF: CT17
MATERIAL NO. OF CSA

NO. CORES k.c.mil(mm2)

IDENTIFICATION: SINGLE PHASE APPLICATION

Cores - Red/Black/Green-Yellow

CT17/66 3 2.96 (1.5)

CT18/67 3 4.9 (2.5)

CT17/68 3 7.9 (4.0)

CT17/69 3 11.8 (6.0)

CT17/70 3 19.7 (10.0)

CT17/71 3 31.6 (16.0)

CT17/72 3 50 (25.0)

CT17/73 3 69 (35.0)
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.18 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 1

REF : CT18

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : STR CU/EPR/EVA

USE : Lighting and Power Distribution non fire survival use in

continuously manned areas.
Not suitable for hazardous (classified) areas.

JACKET (SHEATH) : White/self coloured preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name, voltage grade and NON-ARMOURED

permanently marked, preferably embossed at ≤ 3 m intervals.

Cores - Colour coded insulation, Red, Black, Green/Yellow for Single

Phase applications.

CONSTRUCTION : Stranded metal coated copper conductors, Ethylene Propylene

Rubber Insulation Cores laid up, sheathed with EVA
Compound.

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature Index > 536°F (280°C).
PROPERTIES HCl Emission ≤ 0.5% by weight of compound at
1472°F (800°C).
NEMA WC3 (IEC 332 - Part 3 Category A, Reduced
Propagation).

SHEATH : Tear strength 8N/mm2 minimum.

MECHANICAL Tensile Strength 15N/mm2 minimum.
PROPERTIES Elongation at Break: 160% minimum.

STANDARDS & : USA - NEMA WC3/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded conductor.
BS 6899 for EPR Insulation Type GP 4.
BS 6724 for Outer Sheathing.
BS 6883 for General Construction, Dimensions and Tests.
BS 6724 for Sheath Abrasion Test.

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

MATERIAL NO. NO. OF CSA

CORES k.c.mil (mm2)

CT19/1 3 2.96 (1.5)

CT19/2 3 4.9 (2.5)

CT19/3 3 7.9 (4.0)

CT19/4 3 11.8 (6.0)

4.15.19 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 1

 GENERAL ENGINEERING SPECIFICATION GES L.02
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REF : CT19

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : STR CU/MT/EPR/EVA

USE : Lighting and Power Distribution fire survival use in

continuously manned areas. Not suitable for hazardous
(classified) areas.

JACKET (SHEATH) : White/self coloured preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name, voltage grade and NON-ARMOURED

permanently marked, preferably embossed at ≤ 3 m intervals.

Cores - Colour coded insulation, Red, Black, Green/Yellow for Single

Phase applications.

CONSTRUCTION : Stranded metal coated copper conductors.

Mica/Glass tape.
Ethylene Propylene Rubber Insulation Cores laid up Sheathed
with EVA Compound.

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature Index > 536°F (280°C).
PROPERTIES HCl Emission ≤ 0.5% by weight of compound at
1472°F (800°C).
NEMA WC3 Part 6 (IEC 331 - Enhanced to 1832°F (1000°C)
3 hour Fire Resistance).
NEMA WC3 Part 6 (IEC 332 - Part 3 Category A, Reduced
Propagation).

SHEATH : Tear strength 8N/mm2 minimum.

MECHANICAL Tensile Strength 15N/mm2 minimum.
PROPERTIES Elongation at Break: 160% minimum.

STANDARDS & : USA - NEMA WC3/NFPA 70 Section 3.2.2.

SPECIFICATIONS BS/IEC - BS 6360 - for stranded conductor.
BS 6899 for EPR Insulation Type GP 4.
BS 6724 for Outer Sheathing.
BS 6883 for General Construction, Dimensions and Tests.
BS 6724 for Sheath Abrasion Test.

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

MATERIAL NO. NO. OF CSA

CORES k.c.mil (mm2)

CT19/1 3 2.96 (1.5)

CT19/2 3 4.9 (2.5)

CT19/3 3 7.9 (4.0)

CT19/4 3 11.8 (6.0)

4.15.20 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

 GENERAL ENGINEERING SPECIFICATION GES L.02
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REF : CT20

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : STR CU/MP/GSWB/IMP

USE : Lighting and Power Distribution (Instrumentation and

Telecommunication) non fire survival for use in continuously
manned areas.

JACKET (SHEATH) : White/self coloured preferred, black acceptable.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name, voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.

Cores - Colour coded insulation to BS 6883 (preferred) or printed

numbers for 1,2,3 and 4 core cables.
Colour coded insulation with Red, Black, Green/Yellow for 3
core cables in single phase applications preferred.
White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded metal coated copper conductors Modified Polyester

Insulation.
Cores laid up, Galvanised Steel Wire Braid, sheathed with
Irradiated Modified Polyolefin compound.

FIRE : Oxygen Index ≥ 32.

PERFORMANCE Temperature Index > 536°F (280°C).
PROPERTIES HCl Emission ≤ 0.5% by weight of compound at
1472°F (800°C).
ANSI/NFPA 262-1990 (IEC 332 - Part 3 Category A,
Reduced Propagation).
Low smoke, low Halogen (LSH) properties.

STANDARDS & : USA - NFPA 70 Section 3.2.2.

SPECIFICATIONS BS 6360 for stranded conductor.
BS 6883 for General Construction, Dimensions and Tests.
BS 6724 for Sheath Abrasion Test.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.20 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT20
MATERIAL NO. NO. OF CSA MATERIAL NO. NO. OF CSA

CORES k.c.mil (mm2) CORES k.c.mil(mm2)

CT20/1 2 2.96 (1.5) CT20/33 12 2.96 (1.5)

CT20/2 2 4.9 (2.5) CT20/34 12 4.9 (2.5)

CT20/3 2 7.9 (4.0) CT20/35 19 2.96 (1.5)

CT20/4 2 11.8 (6.0) CT20/36 19 4.9 (2.5)

CT20/5 2 19.7 (10.0) CT20/37 27 2.96 (1.5)

CT20/6 2 31.6 (16.0) CT20/38 27 4.9 (2.5)

CT20/7 2 50 (25.0) IDENTIFICATION: SINGLE PHASE APPLICATION

Cores - Red/Black/Green-Yellow

CT20/8 2 69 (35.0) CT20/39 3 2.96 (1.5)

CT20/9 2 99 (50.0) CT20/40 3 4.9 (2.5)

CT20/10 2 138 (70.0) CT20/41 3 7.9 (4.0)

CT20/11 3 2.96 (1.5) CT20/42 3 11.8 (6.0)

CT20/12 3 4.9 (2.5) CT20/43 3 19.7 (10.0)

CT20/13 3 7.9 (4.0) CT20/44 3 31.6 (16.0)

CT20/14 3 11.8 (6.0) CT20/45 3 50 (25.0)

CT20/15 3 19.7 (10.0) CT20/46 3 69 (35.0)

CT20/16 3 31.6 (16.0)

CT20/17 3 50 (25.0)

CT20/18 3 69 (35.0)

CT20/19 3 99 (50.0)

CT20/20 3 138 (70.0)

CT20/21 4 2.96 (1.5)

CT20/22 4 4.9 (2.5)

CT20/23 4 7.9 (4.0)

CT20/24 4 11.8 (6.0)

CT20/25 4 19.7 (10.0)

CT20/26 4 31.6 (16.0)

CT20/27 4 50 (25.0)
 GENERAL ENGINEERING SPECIFICATION GES L.02
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CT20/28 4 69 (35.0)

CT20/29 4 99 (50.0)

CT20/30 4 138 (70.0)

CT20/31 7 2.96 (1.5)

CT20/32 7 4.9 (2.5)

4.15.21 POWER AND CONTROL CABLE SPECIFICATION Page 1 of 2

REF : CT21

TYPE : LV, 0.6/1.0 kV Grade

ABBREVIATION : Single Core Teck

Multicore Teck

USE : Power Distribution and Control general use (excluding

continuously manned areas).

JACKET (SHEATH) : Black preferred.

COLOUR

IDENTIFICATION

Jacket (Sheath) - Manufacturer's name and voltage grade permanently marked,

preferably embossed at ≤ 3 m intervals.

Cores - Colour coded insulation to NEMA WC5/WC57 (BS 6346) or

printed numbers for 1,2,3 and 4 core cables.
Colour coded insulation, Red, Black, Green/Yellow for 3 core
cables in single phase applications preferred.
White insulation and black printed numbers at ≤ 75 mm
intervals for 7 to 27 core cables.

CONSTRUCTION : Stranded plain copper conductors.

Cross-linked Polyethylene insulation.
Stranded bare copper grounding conductor.
Polyvinyl Chloride inner jacket.
Single core - Aluminium Inter-locking Armour.
Multicore - Galvanised Steel Inter-locking Armour.
Polyvinyl Chloride Jacket (oversheath).

FIRE : CSA Flame Test Rating FT1 and FT4.

PERFORMANCE HCl Emission ≤ 17 % by weight of compound at
PROPERTIES 1472°F (800°C).

STANDARDS & : CSA Standard C22.2 No 131.

SPECIFICATIONS CSA Standard C22.2 N0 174.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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4.15.21 (Cont/d) Page 2 of 2

TABLE OF MATERIALS : Note k.c.mil = (mm2) x 1.974

REF: CT21
MATERIAL NO OF CORES CSA MATERIAL NO NO. OF CSA

NO. k.c.mil(mm2) CORES k.c.mil/(mm2)

CT21/1 1 50 (25.0) CT21/34 3 237 (120.0)

CT21/2 1 99 (50.0) CT21/35 3 296 (150.0)

CT21/3 1 138 (70.0) CT21/36 4 2.96 (1.5)

CT21/4 1 188 (95.0) CT21/37 4 4.9 (2.5)

CT21/5 1 237 (120.0) CT21/38 4 7.9 (4.0)

CT21/6 1 296 (150.0) CT21/39 4 11.8 (6.0)

CT21/7 1 365 (185.0) CT21/40 4 19.7 (10.0)

CT21/8 1 474 (240.0) CT21/41 4 31.6 (16.0)

CT21/9 1 592 (300.0) CT21/42 4 50 (25.0)

CT21/10 1 790 (400.0) CT21/43 4 69 (35.0)

CT21/11 1 987 (500.0) CT21/44 4 99 (50.0)

CT21/12 1 1244 (630.0) CT21/45 4 138 (70.0)

CT21/13 2 2.96 (1.5) CT21/46 4 188 (95.0)

CT21/14 2 4.9 (2.5) CT21/47 4 237 (120.0)

CT5/15 2 7.9 (4.0) CT21/48 4 296 (150.0)

CT21/16 2 11.8 (6.0) CT21/49 4 365 (185.0)

CT21/17 2 19.7 (10.0) CT21/50 7 2.96 (1.5)

CT21/18 2 31.6 (16.0) CT21/51 7 4.9 (2.5)

CT5/19 2 50 (25.0) CT21/52 12 2.96 (1.5)

CT21/20 2 69 (35.0) CT21/53 12 4.9 (2.5)

CT21/21 2 99 (50.0) CT21/54 19 2.96 (1.5)

CT21/22 2 138 (70.0) CT21/55 19 4.9 (2.5)

CT21/23 3 2.96 (1.5) CT21/56 27 2.96 (1.5)

CT21/24 3 4.9 (2.5) CT21/57 27 4.9 (2.5)

CT21/25 3 7.9 (4.0) IDENTIFICATION: SINGLE PHASE APPLICATIONS

Cores - Red/Black/Green-Yellow

CT21/26 3 11.8 (6.0) CT21/58 3 2.96 (1.5)

CT21/27 3 19.7 (10.0) CT21/59 3 4.9 (2.5)

CT21/28 3 31.6 (16.0) CT21/60 3 7.9 (4.0)

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CT21/29 3 50 (25.0) CT21/61 3 11.8 (6.0)

CT21/30 3 69 (35.0) CT21/62 3 19.7 (10.0)

CT21/31 3 99 (50.0) CT21/63 3 31.6 (16.0)

CT21/32 3 138 (70.0) CT21/64 3 50 (25.0)

CT21/33 3 188 (95.0) CT21/65 3 69 (35.0)

 GENERAL ENGINEERING SPECIFICATION GES L.02
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5.0 NEMA/IEC DIFFERENCES

5.1 General

This specification is primarily written for cables manufactured in accordance with the American
(NEMA) Standards.

If it is necessary or advantageous to purchase equipment in accordance with International (IEC)

Standards, the specification can still be utilised but the salient differences occurring should be noted as
detailed below.

5.2 Salient Differences

This section does not attempt to list every difference between American (NEMA) standards and IEC
standards, but covers only those salient differences that could affect the final installation if misunderstood
or not properly addressed during the design phase.

5.2.1 Units - SI Units

The NEMA Standards in many cases utilise imperial units (feet, pounds, degrees fahrenheit, etc), whilst the
IEC Standards utilise SI units (metres, grammes, degrees celsius etc).

Note:

For electrical equipment, the (American) Institute of Electrical and Electronic Engineers (IEEE) have
recommended that the use of the imperial (British-American) units in use be reduced as rapidly as possible
in favour of the SI units, with certain implementations such as the use of horsepower being phased out first.

5.2.2. Cable Conductor Cross Sectional Area (CSA)

IEC cable CSAs are always in metric dimensions (mm2). American conductor sizes are often American
Wire Gauge (AWG) for the smaller sizes and circular mils (c.mil) for larger sizes. However because
circular mil is a term generally used in the USA and based on the mil (one thousandth of an inch), this
specification refers solely to c.mil and not to AWG; the following table gives the conversion:

AWG k.c.mil AWG k.c.mil AWG k.c.mil

22 0.640 13 5.18 4 41.74
21 0.812 12 6.53 3 52.62
20 1.02 11 8.23 2 66.36
19 1.29 10 10.38 1 83.69
18 1.62 9 13.09 1/0 105.6
17 2.05 8 16.51 2/0 133.1
16 2.58 7 20.82 3/0 167.8
15 3.26 6 26.24 4/0 211.6
14 4.11 5 33.09 - 250*
- 300*
- 350*
- 400*
- 450*
- 500*

Note: k.c.mil = (mm2) x 1.974 or (mm2) = 0.507 x k.c.mil

* Sizes asterisked are commercially available k.c. mil cables
5.2.3 Common Conversions (Imperial to Metric)

To convert values in a non-metric unit to the approximate value in an appropriate metric unit, multiply the
value in the non-metric unit by the appropriate number from the following table:
 GENERAL ENGINEERING SPECIFICATION GES L.02
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From To Multiplier
inches millimeters (mm) 25.4
mil (one thousandth of an inch) millimeters (mm) 0.0254
feet (ft) meter (m) 0.305
ohms per 1000 feet (Ω/1000 ft) milliohms per meter (mΩ/m) 3.28
square inch (in2) square millimeter (mm2) 645
thousand circular mils (k.c.mil) square millimeter (mm2) 0.507
kilovolts per inch or volts per mil megavolts per meter or kilovolts 0.0394
(kV/in or V/mil) per millimeter (MV/m or kV/mm)
pounds per square inch (psi) kilopascals (kPa) 6.89
pounds tension or force per inch (lb/in) newtons per meter (N/m) 175
megohms -1000 ft (MΩ-1000 ft) megohms-meter (MΩ-m) 305
gigahohms-1000 ft (GΩ-1000 ft) gigaohms-meter (GΩ-m) 305
liquid ounces (liq oz) cubic centimeter (cm3) 29.6

Additionally

The Fahrenheit equivalents for Celsius degrees may be calculated by the equation:

°F=(1.8 x°C) + 32

The ounce equivalents to grams may be calculated by dividing the number of grams by 28.4

The ohm.cmil per foot equivalents to nanohm-meter may be calculated by multiplying the nanoohm-meter
value by 0.602.

5.2.4 Electrical Supply System Characteristics

There are voltage and frequency differences which are fully detailed in Section 3.3. However, this should
not be a problem as cables are made available for a range of voltages rather than a specific voltage, e.g.
electric power and control cables from the UK are manufactured for low voltage systems up to 1000 volts
(phase to phase) which covers the single and low voltage ranges shown in Section 3.3 of this specification.

Provided the Owner's data clearly specifies in the appropriate place in the Data Sheets, the 'U/Uo' system
voltage, the correct cable should be provided by the Vendor/Contractor.

5.2.5 Grounding

Concerned with the nature and location of an intentional electrical interconnection between the Electrical
System Conductors and Ground.

In British Practice, the terms "Grounding" and "Ground" are replaced by "Earthing" and "Earth".

5.2.6 NFPA 70

The National Electrical Code gives a detailed breakdown (Table 310.13) for "Conductor Applications and
Insulations", with specific recommendations for Insulation and outer covering etc, for various locations and
the associated cable type letter.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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The BS/IEC standards generally only give the cable details without such detailed recommendations as to its
usage; this decision is left to the engineer designing the installations.

This should not be a problem as in either case, the Owner will need to check on the area the cable is to be
used and decide which is suitable.

5.2.7 Test Voltages

These vary between American and IEC standards but are clearly defined in the relevant standard and are
easily checked by the Owner.

5.2.8 Usage

The American NFPA 70 (National Electrical Code) defines many different types for different installations,
e.g, 'RHW' for wet and dry locations, 'RHH' for dry locations, IEC/BS practice is to utilise one basic type
for multi-purpose applications, particularly when considering wet or dry locations. Table 3.10.13 in the
National Electrical Code details many of the types.

5.2.9 Colour Coding

There are differences in the method of colour coding both cable sheaths and conductors between the
American and IEC codes; again, by referring to the relevant specification, the differences are clearly
defined.

6.0 INSPECTION

6.1 Procedures

The inspection requirements are covered by the document "General Conditions of Purchase" which forms
part of the Purchase Order/Contract. Additional requirements are given below.

(a) The Vendor/Contractor shall allow the Inspector free access to all areas of manufacture,
fabrication, assembly and testing.

(b) The Vendor/Contractor always has the responsibility to provide adequate quality control and
inspection of equipment and materials as defined in ISO 9000. Any inspection by Owner or his
Inspector shall not relieve the Vendor/Contractor of these responsibilities or those under his
guarantees.

(c) Any defects noticed in the course of fabrication shall be brought to the attention of the Inspector,
who shall decide if the faulty material or workmanship should be repaired or rejected.

(d) If inspection is waived, the required data shall be forwarded to the Owner. If submission of data is
not requested, all data shall be retained by the Vendor/Contractor for issue to the Owner on
demand, for at least five years.

(e) The Vendor/Contractor shall provide a safe working environment for the Inspector and alert the
Inspector of potential hazards.

6.2 Scope

Inspector shall inspect the cables to ensure that they comply with the requirements of the latest revision of
this specification and Data Sheets, drawings or other attachments to the material requisition, and the latest
revision of the Vendor/Contractor's documentation and data relating to the specific Purchase
Order/Contract.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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In particular, at least the following shall be checked:

(a) identification,

(b) dimensions,

(c) certification/approvals markings,

(d) nameplates (on cable drums).

Inspector shall ensure that any shortcomings in the Vendor/Contractor's documentation or data are rectified
before any cables are accepted for shipment.

6.3 Nameplates (On Cable Drums)

6.3.1 Information to be given in all cases

Nameplates shall be non-deteriorating stainless steel (or equal).

Nameplates shall be permanently fixed, and include the following minimum information:

(a) manufacturer's name,

(b) cable size and number of cores,
(c) cable length,
(d) order number,
(e) order item number,
(f) weight,
(g) drum number.

7.0 TESTING

7.1 Statutory Tests

Tests shall be performed in accordance with the applicable codes, the requirements of the Data Sheets and
include as a minimum the following Routine and Sample Tests.

a) Routine Tests on All Completed Cable

- conductor resistance,
- voltage test,

- insulation resistance test on cables up to 1000 V rating,

- partial discharge test on cables in excess of 1000 V Line to Line rating,
- cable marking (jacket-sheath and conductors).

b) Sample Tests on 10% of Completed Cables or Components taken from Completed Cables

- conductor construction,
- conductor screen application,
- insulation thickness,
- semi-conducting insulation shield (screen) application:

(a) taped shield (screen),

 GENERAL ENGINEERING SPECIFICATION GES L.02
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(b) extruded shield (screen).

- copper tape shield (screen):

(a) application,
(b) thickness.

- inner sheath thickness,

- wire braid or armour coverage,
- outer jacket (sheath) thickness,
- HCl emission of inner and outer jacket (sheath),
- measurement of thickness of copper tape.

c) Type Tests

To be effected only if requested by Owner or if Vendor/Contractor cannot provide documentary evidence

of Type Testing for the cables in question:

- resistivity of extruded semi-conducting conductor screen (radial field cables above 1000 V grade),
- resistivity of extruded semi-conducting insulation screen (radial field cables above 1000 V grade),
- resistivity of taped semi-conducting conductor screen,
- resistivity of taped semi-conducting insulation screen (radial field cables above 10000 V grade),
- cold strippability of extruded semi-conducting insulation screen (radial field cables above
1000 V grade),
- copper tape screen material (radial field cables above 1000 V).

Sequential tests (radial field cables above 1000 V grade) comprising:

(a) partial discharge,

(b) bending,
(c) power factor voltage,
(d) power factor temperature,
(e) heating cycle,
(f) impulse voltage withstand,
(g) voltage test for four hours.

Performance under fire conditions:

(a) vertical burning (single cable),

(b) reduced flame propagation (bunched cables).

Insulation Material (inner and outer sheath):

(a) material,
(b) tear resistance,
(c) elongation at break,
(d) oil resistance.

Adherence of screens at short circuit,

Temperatures - Wire braid/Armour:

(a) material,
(b) diameter.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Smoke emission.

7.2 Factory Acceptance Testing

7.2.1 Attendance

Where requested by the Owner at contract negotiation stage, factory acceptance testing shall be undertaken
in the presence of the Inspector.

7.2.2 Factory Tests

The Factory tests shall include the following necessary Routine, Sample and Type tests to the relevant
national standard to ensure that the specification for the cables have been met at the rated environmental
conditions:

7.2.3 Factory Test Schedule Provision

After Factory Acceptance Test schedules have been completed, the results shall be shipped with the cables.

7.3 Test Procedures

7.3.1 In all cases the Vendor/Contractor shall submit his test procedures in writing to the Owner for approval
prior to the start of the testing programme.

7.4 Site Acceptance Test Requirements

7.4.1 Test Schedules

The Vendor/Contractor shall submit a schedule of Site Acceptance Tests that are to be undertaken to ensure
that the equipment is satisfactory.

The test schedules shall be approved by the Owner. There shall be a separate set of acceptance tests for
each Transformer supplied.

7.4.2 Initial Acceptance Tests

The initial acceptance tests shall be performed by the Vendor/Contractor when all relevant equipment has
been installed.

7.4.3 Final Acceptance Tests

Fourteen days after the systems have been put into service, or fourteen days after the initial acceptance
tests, whichever is the earliest, the Final Acceptance Tests shall be effected by the Vendor/Contractor, and
be witnessed by the Inspector.

7.5 Test Certificates

7.5.1 Test Certificates

Final acceptance of the cables will be given following satisfactory Factory Acceptance Tests.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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All copies of test certificates shall be furnished with final drawings as called for in documentation section.
The Factory Acceptance Tests shall be witnessed by the Inspector who shall retain one copy of the certified
tests.

7.6 Test Equipment

7.6.1 Supply

The Vendor/Contractor shall supply a set of test equipment if it is required.

7.6.2 Test Accessories

All necessary test leads, power cords and ancillaries shall be provided.

Note:

All instrument and apparatus used in the performance of the tests shall have been calibrated to an agreed
standard at a laboratory of National standing within the period of 15 months of the test date.

The cost of carrying out such calibrations shall be borne by the Vendor/Contractor in all cases.

8.0 DOCUMENTATION

8.1 Introduction

8.1.1 This section covers the documentation required for the design, selection, fabrication, inspection and testing
for all the equipment, components and services to be provided against this specification.

8.1.2 The detailed list of documents that are required is included with the Purchase Order/Contract, however as a
minimum the following listed documents will be provided by the Vendor/Contractor.

. General Arrangement (Cable Construction),

. Electrical Data (including weight and dimensions),
. Test Certificates.

8.1.3 The documents as listed may be considered as a minimum requirement; all details to confirm compliance
with the relevant specifications, and to allow a full and continued appraisal to be made of the
Vendor/Contractors proposals and interpretations of the ordered equipment, should be submitted in
accordance with the schedule specified in the Purchase Order/Contract.

8.1.4 Any production or procurement undertaken by the Vendor/Contractor which is prior to the relevant
documentation being submitted and reviewed by the Owner is at the Vendor/Contractors risk.

8.1.5 On all documentation the Purchaser Order/Contract number, equipment title, tag number and project name
shall be quoted.

8.1.6 All documentation shall be checked and signed by the checker before submission.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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Rev 0 1999
8.2 Schedules and Reports

8.2.1 The Vendor/Contractor shall submit with his tender a preliminary quality control plan and proposals for
Factory acceptance and site acceptance tests.

8.2.2 The Vendor/Contractor shall submit with his tender documentation a statement of proposed Sub-
Vendors/Sub-Contractors, a document submission schedule for all documents based on a review of cycle of
three weeks and outline programme for procurement and production activities.

8.2.3 The Vendor/Contractor shall incorporate any revisions agreed with the Owner during the enquiry review
stage and submit revised tender documentation for approval.

8.2.4 Monthly reports shall be submitted by the Vendor/Contractor detailing design, procurement, production
and documentation activities. The format of which shall be agreed with the Owner.

8.3 Data and Calculations

8.3.1 The Vendor/Contractor shall supply with his tender completed Data Sheets containing all the relevant
information necessary for appraisal of the design by the Owner.

8.3.2 Project specific instructions will be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted, and the methods of submission.

8.3.3 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.

8.3.4 All calculations shall be carried out in clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be
clearly referenced.

8.3.5 Computer calculations will only be acceptable if all input is shown, together with calculated values of
intermediate terms and factors and options chosen, as well as final calculated dimensions, stresses or other
values and the computer program has been validated to the satisfaction of the Owner.

8.3.6 Calculations and drawings that are interdependent, i.e. foundation loading and equipment footprint, shall be
presented for appraisal together.

8.4 Drawings

8.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
and/or the Inspection Authority for review and approval.

8.4.2 The components and process to produce the ordered equipment shall be shown in sufficient detail to be
fully appraised eg, outline drawings, components list and schematic diagrams.

8.4.3 General arrangement drawings shall be to scale and show the relative location and main dimensions of all
components including elevations.

8.4.4 Detail drawings which may be included on the general arrangement shall include thicknesses and
dimensions of all components.

8.4.5 As-built drawings may be the general arrangement drawings marked-up with the actual as-built dimensions.

8.5 Final Records, Documents and Manuals

8.5.1 Two copies of the Data Dossier shall be supplied, and shall be a record of the manufacturing process.
 GENERAL ENGINEERING SPECIFICATION GES L.02
POWER AND CONTROL CABLES Page 82 of 74
Rev 0 1999
Where stated in the Purchase Order/Contract, it shall contain the following:

- general arrangement drawing and bill of material,

- the quality control plan,
- material certificates,
- chemical analysis certificates,
- positive material identification certificates,
- NDT procedures and records,
- performance test procedures, and test certificate,
- non-conformity records,
- approvals by the Independent Inspection Authority,
- certificate of conformity,
- Owner's release certificate.

8.5.2 Six sets of the Installation, Operations and Maintenance Manual (IOM) shall be specifically compiled for
the equipment supplied. A compendium of manufacturer's data for a range of like products is not
acceptable. Where relevant, the IOM shall contain the following:

- a description of the equipment,

- the master document list and certified copies of the key drawings,
- packing, shipping and site preservation instructions,
- step by step installation instructions,
- spare parts ordering information.

The IOMs shall be presented in A4 format, and be securely bound in heavy duty 4 ring binders.

8.5.3 The Vendor/Contractor shall produce as built documents revised to indicate field changes.

8.5.4 The Vendor/Contractor shall supply one set of mylar original drawings.

8.5.5 Electronic Data Format (EDF)

All documentation (drawings, calculations and Data Sheets etc.) shall be produced by the
Vendors/Contractors in electronic format.

The format shall be compatible with that used by the Owner and shall be agreed at the commencement of
the contract.

In addition to the "hard copies" required under the contract, copies of the electronic records shall be issued
to the Owner for all approved documentation, this forming part of the Vendor/Contractor's contractual
obligations.

9.0 PRIOR TO SHIPMENT

9.1 Painting and Coatings

Not applicable.

9.2 Spares

Not applicable.
 GENERAL ENGINEERING SPECIFICATION GES L.02
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9.3 Packing and Storage

This section describes the minimum requirements for the preservation and protection of all cables during
the sea and land transportation and storage prior to installations.

The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24
months shall be assumed. Packing to be suitable for sea freight.

(a) After mechanical completion at the works, the cables shall be left in a clean dry condition.

(b) The Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent
damage during shipment.

The Vendor/Contractor shall submit his procedures for packing and preservation for review by the Owner.

9.4 Shipping

Detailed shipping arrangements are covered by the contract and the Purchase Order/Contract.

The cables shall not leave the Vendor/Contractor's works for shipment until the release has been approved
by the Owner's Inspector.

9.5 Warranty

The Vendor/Contractor shall warrant all material and services supplied against any defect for a period of
twelve (12) months after commissioning, or twenty-four (24) months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.
 DATA SHEET No.

ELECTRIC POWER AND CONTROL CABLES

P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 1 of 2
SERVICE SYSTEM VOLTS Hz ( kA for sec)
DATA BY OWNER

1 VENDOR / CONTRACTOR
2 U.S. METRIC CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE
3 ORDER ITEM NO. n/a n/a
4 NOC SPEC. L.2 CABLE (CT) REF n/a n/a
5 NO. OF CORES n/a n/a
6 CONDUCTOR CSA k.c.mil² mm²
7 CONDUCTOR TYPE (Cu/Al) n/a n/a
8 INFORMATION FROM VENDOR / CONTRACTOR
9
10 DIMENSIONAL DATA CABLE UNITS CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE
11 U.S. METRIC
12 CONDUCTOR STRANDING n/a n/a
13 CONDUCTOR DIAMETER nom. mil mm
14 INSULATION THICKNESS min. mil mm
15 CORE DIAMETER nom. mil mm
16 BEDDING THICKNESS min. mil mm
17 DIA. UNDER ARMOUR min. mil mm
18 max. mil mm
19 ARMOUR THICKNESS nom. mil mm
20 DIA. OVER ARMOUR nom. mil mm
21 SHEATH THICKNESS nom. mil mm
22 OVERALL DIAMETER min mil mm
23 max mil mm
24
25 CHARACTERISTICS
26
27 APPROX. CABLE WEIGHT nom. lb/ft kg/m
28 MIN. BENDING RADIUS min. in mm
29 MAX. PULLING TENSION max. lbf kgf
30
31 DC COND. RES @ 68°F (20°C) max ohm/1000ft ohm/km
32 AC COND. RES. @ 194°F (90°C) max. ohm/1000ft ohm/km
33 REACTANCE @ 50 HZ nom. ohm/1000ft ohm/km
34 REACTANCE @ 60 HZ nom. ohm/1000ft ohm/km
35 IMPEDANCE @ 50 HZ, 194°F (90°C) nom. ohm/1000ft ohm/km
36 IMPEDANCE @ 60 HZ, 194°F (90°C) nom. ohm/1000ft ohm/km
37 INDUCTANCE nom. mH/1000ft mH/km
38 CAPACITANCE (core/core) nom. micF/1000ft microF/km
39 CAPACITANCE (core/earth) nom. micF/1000ft microF/km
40 COND. LOOP RESIS. max. ohm/1000ft ohm/km
41 LOOP SELF INDUCT. max. micH/1000ft microH/km
42 L/R RATIO max.
43 ARMOUR CSA nom. k.c.mil² mm²
44 ARMOUR RESISTANCE nom. ohm/1000ft ohm/km
45 VOLTS DESIGNATION (kV)Uo/U (kV)Uo/U
Revision No./Date 0
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
K:\nocspecs\SPECIFICATIONS\l-series\l-02\dl0201r0.xls Sheet1
 DATA SHEET No.

ELECTRIC POWER AND CONTROL CABLES

P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 2 of 2
SERVICE SYSTEM VOLTS Hz ( kA for sec)
INFORMATION FROM VENDOR / CONTRACTOR (contd)

1 VENDOR / CONTRACTOR
2 CHARACTERISTICS (contd) CABLE UNITS CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE
3 U.S. METRIC
4 CURRENT RATING {86/113°F (30/45°C)} (AIR) amps amps
5 CURRENT RATING 59°F (15°C) (DUCTS) amps amps
6 CURRENT RATING 59°F (15°C) (GROUND) amps amps
7 CONDUCTOR S/C RATING
8 1 sec {150-320°F (70-160°C) / 194-482°F (90-250°C)} kA kA
9 0.5 sec {150-320°F (70-160°C) / 194-482°F (90-250°C)} kA kA
10 0.2 sec {150-320°F (70-160°C) / 194-482°F (90-250°C)} kA kA
11 ARMOUR S/C RATING
12 1 sec {150-320°F (70-160°C) / 194-482°F (90-250°C)} kA kA
13 0.5 sec {150-320°F (70-160°C) / 194-482°F (90-250°C)} kA kA
14 0.2 sec {150-320°F (70-160°C) / 194-482°F (90-250°C)} kA kA
15 VOLT DROP V0 (dc) mV/A/ft mV/A/m
16 VOLT DROP V50 I PHASE mV/A/ft mV/A/m
17 VOLT DROP V50 3 PHASE mV/A/ft mV/A/m
18 VOLT DROP V60 1 PHASE mV/A/ft mV/A/m
19 VOLT DROP V60 3 PHASE mV/A/ft mV/A/m
20
21 HCl EMISSION OF SHEATH max.
22 OXYGEN INDEX SHEATH nom.
23 TEMP. INDEX OF SHEATH nom.
24 IEC 332-1 (see note 2)
25 IEC 332-3 (see note 2)
26 IEC 331 {3hr, 1832°F (1000 °C)} (see note 2)
27
28 GLAND DATA
29
30 GLAND REF (BICC)
31 GLAND REF (CMP)
32 GLAND REF (HAWK)
33 GLAND REF ( )
34 GLAND REF ( )
35
36 DRUM NO. n/a n/a
37
38
39
40 NOTES
41
42 1 FOR CURRENT RATINGS (LINES 4, 5 AND 6), VENDOR / CONTRACTOR TO ADVISE TEMPERATURE VARIATION FACTOR TO
43 BASE 30/45 AND 15°C SHOWN
44 2 REFER TO RELEVANT NEMA/ICEA STANDARD FOR EQUIVALENT TEST TO IEC 331
45
Revision No./Date 0
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
K:\nocspecs\SPECIFICATIONS\l-series\l-02\dl0201r0.xls Sheet2
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES L.31

AREA CLASSIFICATION

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES L.31
AREA CLASSIFICATION Page 2 of 26
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 5
1.3 Data Sheets 5
1.4 Scope of Supply 5

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 9

3.0 DESIGN & PERFORMANCE 10

3.1 Environmental Conditions 10

3.2 Codes and Standards 10
3.3 Principles of Hazard Reduction 11
3.4 Area Classification 12
3.5 Gas (Material) Grouping 14
3.6 Temperature Classification 15

4.0 APPLICATION 16

4.1 Introduction 16
4.2 Step 1 - Need for Classification 17
4.3 Step 2 - Assignment of Classification 17
4.4 Step 3 - Extent of Classified Locations 18
4.5 Step 4 - Determination of Group 18
4.6 Documentation 18

5.0 EQUIPMENT AND PIPING 18

5.1 Introduction 18
5.2 Leakage from Pumps 18
5.3 Leakage from Compressors 19
5.4 Leakage from Flanges and Joints 20
5.5 Leakage from Valve Glands 21
5.6 Relief Valve Discharge to Atmosphere 21
5.7 Venting of Small Quantities of Gas (except Tanks) 22
5.8 Process Drains and Sample Points 22
5.9 Fixed Roof Tank Vent 23
5.10 Floating Roof Tank Seals 23
5.11 Loading Operations 24
5.12 Vapour from Oil/Water Separator 24

INDEX
 GENERAL ENGINEERING SPECIFICATION GES L.31
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SEC TITLE PAGE

6.0 NEMA/IEC DIFFERENCES 25

6.1 General 25
6.2 Salient Differences 25

7.0 LIST OF EQUIPMENT FOR AREA CLASSIFICATION 26

(LEAC) SUB-INDEX 32
 GENERAL ENGINEERING SPECIFICATION GES L.31
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 The main purpose of this Specification is to provide guidelines for classifying locations at refineries,
onshore oil and gas installations and processing facilities for the selection and installation of electrical
equipment & instruments. Basic definitions given in NFPA No. 70, the National Electrical Code, (NEC),
have been followed in developing this document. This specification is only a guide and requires the
application of sound engineering judgement. Reference is also made to International and European
Practices.

1.1.2 Electrical installations in 'Class 1' areas (see Section 1.1.6, below for details of Class 2 and Class 3
exclusions) where flammable liquids or gases are produced, processed, stored or otherwise handled can be
suitably designed if the locations of potential sources of release and accumulation are clearly defined.
Once a location has been classified, requirements for Electrical Equipment, Instruments and associated
wiring, should be determined from applicable publications. Applicable publications include NFPA No. 70
(NEC) and API RP500.

1.1.3 This General Engineering Specification applies to the classification of locations for both temporarily and
permanently installed Electrical Equipment and instruments.

1.1.4 Recommendations for determining the degree and extent of classified locations for specific situations
commonly encountered in petroleum facilities are given in Sections A, B & C of API RP500. While it is
important for area classifications at refineries, production and drilling facilities, and pipeline facilities to
agree as far as is practicable, there are differences in production, drilling, transportation and refining
facilities. Some differences include the types and quantities of products handled, the physical size of
typical facilities, and varying housing/shelter practices.

Section A of API RP500 is applicable to locations in which flammable petroleum gases and volatile
flammable liquids are processed, stored, loaded, unloaded, or otherwise handled in petroleum refineries.

Section B of API RP500 is applicable to locations surrounding oil and gas drilling and workover rigs and
facilities on land and on marine fixed and mobile platforms where flammable petroleum gas and volatile
liquids are produced, processed, stored, transferred, or otherwise handled prior to entering the
transportation facilities.

Section C of API RP500 is applicable to onshore and offshore facilities handling the delivery of
flammable or combustible petroleum liquids or flammable gases. Pipeline facilities may include pump
and compressor stations, storage facilities, manifold areas, valve sites and pipeline right-of-way areas.

1.1.5 Industry Codes, Guides and Standards

Various organizations have developed numerous codes, guides and standards that have substantial
acceptance by industry and governmental bodies. Codes, guides and standards generally useful in the
classification of locations and in the design and installation of electrical systems are listed in Section 3.2.
These references are not to be considered a part of this Specification except for those particularly
referenced within the text of this Specification.

1.1.6 Exclusions

- The suitability of locations for the placement of non-electrical equipment is not within the scope of
this document.

- Piping systems used for odourized natural gas used as fuel for cooking, heating, air conditioning,
laundry and similar appliances are also beyond the scope of this document.
 GENERAL ENGINEERING SPECIFICATION GES L.31
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Rev 0 1999
- A possible catastrophe such as a well blowout or a process vessel rupture is not covered; such an
extreme condition requires emergency measures at the time of occurrence.

- Area classification relating to flammable dusts (Class 2)

- Area classification relating to flammable fibres (Class 3)

- Fire hazard locations

- Sources of ignition due to normal operating high temperatures (pipe work, exhaust systems etc) and
High Temperature Devices.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved by the Owner.

GES A.06 Site Data

GES B.12 Heating, Ventilation, Air Conditioning

GES L.35 Electrical Equipment in Hazardous Areas

1.3 Data Sheets

There is no requirement for data sheets within this specification.

Using the Area Classification Drawing produced by applying the principles of this Specification, the Data
Sheets for each individual item of equipment will indicate the requirements for the equipment, e.g, Class 1
Division 1, Class 1 Division 2, and Unclassified.

1.4 Drawings

The deliverable to be supplied is a "Hazardous Area Classification Drawing". This drawing is normally
prepared by the Vendor/Contractor's Electrical Design Group after discussions with other Design Groups
to allow purchase and installation of the correct electrical equipment and instruments.

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this Specification are defined as follows:

Associated Apparatus

Apparatus used in intrinsically safe systems in which the circuits are not necessarily intrinsically safe
themselves, but affect the energy in the intrinsically safe circuits and are relied upon to maintain intrinsic
safety. Refer to NEC Article 504-4 for additional details.

Class I Location

A location in which flammable gases or vapours are, or may be, present in the air in quantities sufficient to
produce explosive or ignitible mixtures.

Class I, Division 1 Location

 GENERAL ENGINEERING SPECIFICATION GES L.31
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A location in which ignitible concentrations of flammable gases or vapours are expected to exist under
normal operating conditions or in which faulty equipment might simultaneously release flammable gases
or vapours and also cause failure of electrical equipment. Reference Section 3.4.2 and NEC Article 500-
5(a) for a more complete definition.

Class I, Division 2 Location

A location in which flammable gases or vapours may be present, but normally are confined within closed
systems and are prevented from accumulating by adequate mechanical ventilation. Alternatively, the
location is adjacent to a Division 1 location from which ignitible concentrations might occasionally be
communicated. Reference Section 3.4.2 and NEC Article 500-5(b) for a more complete definition.

Combustible Liquid - Class II, IIIA & IIIB Liquids

A liquid having a flash point at or above 100°F (37.8°C); combustible liquids are sub-divided as follows:-

- Class II Liquids

Those having flash points at or above 100°F (37.8°C) and below 140°F (60°C).

- Class IIIA Liquids

Those having flash points at or above 140°F (60°C) and below 200°F (93°C)

- Class IIIB Liquids

Those having flash points at or above 200°F (93°C)

Flammable Liquid (Class IA, IB and IC Liquids)

A liquid having a flash point below 100°F (37.8°C) and having a vapour pressure not exceeding 40 psia
(2.8 Bara) at 100°F (37.8°C). Flammable (Class I) liquids are subdivided into Classes IA, IB, and IC.
Refer to NFPA No.30 for further details.

Volatile (Flammable) Liquid

A flammable liquid whose temperature is above its flash point, or a Class II combustible liquid having a
vapour pressure not exceeding 40 psia (2.8 bara) at 100°F (37.8°C) whose temperature is above its flash
point.

Combustible Gas or Vapour

Any substance that exists in the gaseous or vapour state at normal atmospheric temperature and pressure,
and that is capable of being ignited when mixed with air.

Drilling Areas

Those areas in which wells are being drilled, recompleted or reworked for the purpose of exploring for or
producing oil or gas. Wells meeting any of the conditions of the above are referred to as "drilling wells".
This does not include wells on which wireline work is being performed through a lubricator or wells into
which or from which pumping equipment is being installed or removed.

Enclosed Area (Room, Building or Space)

 GENERAL ENGINEERING SPECIFICATION GES L.31
AREA CLASSIFICATION Page 7 of 26
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A three-dimensional space enclosed by more than two-thirds (2/3) of the possible projected plane surface
area and of sufficient size to allow the entry of personnel. For a typical building, this would require that
more than two-thirds (2/3) of the walls, ceiling, and/or floor be present.

Enclosure, Electrical

The case or housing of electrical apparatus provided to prevent personnel from accidentally contacting
energized parts and to protect the equipment from physical damage. Certain enclosures also serve to
prevent electrical equipment from being a source of ignition of flammable mixtures outside the enclosure.

Enclosure, Explosion-proof

An enclosure that is capable of withstanding an explosion of a specific gas or vapour within it and of
preventing the subsequent ignition of a flammable gas or vapour that may surround it, and which operates
at such an external temperature that a surrounding flammable gas or vapour will not be ignited.

Flammable

Capable of igniting easily, burning intensely or spreading flame rapidly.

Flammable (Explosive) Limits

The lower and upper percentages by volume of concentration of gas in a gas-air mixture that will form an
ignitible mixture. (Reference NFPA No. 325M).

Flash Point

The minimum temperature at which a liquid gives off vapour in sufficient concentration to form an
ignitible mixture with air near the surface of the liquid. Appropriate test procedures and apparatus are
specified by NFPA No. 30.

Fugitive Emissions

Continuous flammable gas and vapour releases that are relatively small compared to releases due to
equipment failures. these releases occur during normal operation of closed systems from components such
as pump seals, valve packing and flange gaskets. (Reference NFPA No. 30).

Group A

Atmospheres containing acetylene. Refer to NEC Article 500-3, FPN No. 5

Group B

Atmospheres containing hydrogen and other gases. Refer to Section 3.5 and NEC Article 500-3,
FPN No. 6.

Group C

Atmospheres containing hydrogen sulphide and other gases or vapours. Refer to Section 3.4.2 and NEC
Article 500-3, FPN No. 7.

Group D

Atmospheres containing butane, gasoline, hexane, methane, natural gas, propane and most other
hydrocarbon gases and vapours encountered in oil and gas production, refining and pipeline operations.
 GENERAL ENGINEERING SPECIFICATION GES L.31
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Refer to NEC Article 500-3, FPN No. 8.

Hazop

Hazard and Operability Study

High Temperature - Device

A device whose maximum operating temperature exceeds 80 percent of the ignition temperature,
expressed in °C, of the gas or vapour involved.

Highly Volatile Liquids (HVLs)

Liquids whose vapour pressure exceeds 40 psia (2.8 bara) at 100°F (37.8°C).

Ignitible (Flammable) Mixture

A gas-air mixture that is capable of being ignited by an open flame, electric arc or spark, or device
operating at or above the ignition temperature of the gas-air mixture. See "Flammable (Explosive)
Limits."

Ignition (Autoignition) Temperature

The minimum temperature required, at normal atmospheric pressure, to initiate or cause self-sustained
combustion of a flammable mixture independent of any external source of ignition.

Incendiary Energy

Hot particle energy sufficient to ignite a specific ignitible mixture.

Intrinsically Safe System

An assembly of interconnected intrinsically safe and associated apparatus, and interconnecting cables in
which those parts of the system that may be used in hazardous (classified) locations are intrinsically safe
circuits. An intrinsically safe system may include more than one intrinsically safe circuit.

Intrinsically Safe Circuit

A circuit in which any spark or thermal effect is incapable of causing ignition of a flammable mixture in
air under test conditions specified by UL 913.

LEL

Lower Explosive Limit

LFL

Lower Flammable Limit

MESG

Maximum Experimental Safe Gap

NPL

Neutral Pressure Level

 GENERAL ENGINEERING SPECIFICATION GES L.31
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Rev 0 1999

Protected Fired Vessel

Any fired vessel that is provided with equipment (such as flame arresters, stack temperature shutdowns,
forced draft burners with safety controls, and spark arresters) designed to eliminate the air intake and
exhaust as sources of ignition.

Purged Enclosure

An enclosure or building supplied with clean air or an inert gas at sufficient flow and positive pressure to
reduce the concentration of any flammable gases or vapours initially present to an acceptably safe level
and to maintain this safe level by positive pressure with or without continuous flow. Refer to NFPA No.
496 for further details.

Unclassified (Safe) Location

A location not classified as Division 1 or Division 2.

Vapour-Tight Barrier

A barrier that will not allow the passage of significant quantities of gas or vapour at atmospheric pressure.

Ventilation, Adequate

Ventilation (natural or artificial) that is sufficient to prevent the accumulation of significant quantities of
vapour-air mixtures in concentrations above 25 percent of their lower flammable (explosive) limit (LEL).

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a contractor to do part of the work awarded to the contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
 GENERAL ENGINEERING SPECIFICATION GES L.31
AREA CLASSIFICATION Page 10 of 26
Rev 0 1999
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN & PERFORMANCE

3.1 Environmental Conditions

These conditions are fully detailed in GES A.06, and cover the principal site conditions affecting the
electrical equipment including maximum and minimum ambient temperature, seismic data, dust, humidity
and altitude etc.

3.1.1 Internal Environment

Internal equipment shall be housed in an enclosed, air-conditioned equipment room; full details are given
in GES B.12.

3.2 Codes and Standards

3.2.1 General

In general, the requirements specified herein are based on the ANSI/NEMA codes and standards, the most
important of which are listed below. Wherever applicable, equipment and materials shall comply with
these codes and standards.

Unless specified otherwise in the Purchase Order/Contract, the current editions of the codes and standards
at the time of order shall apply.

The Vendor shall operate and supply certification for a Quality System complying with the requirements
of BS EN ISO 9000, Part 1 (Design) Part 2 (Production) and Part 3 (Test and Inspection).

3.2.2 US Codes and Standards

ANSI C2 National Electrical Safety Code (NESC)

ANSI C39.5: Safety Requirements

API RP500: Classification of Locations for Electrical Installations of Petroleum

Facilities.

Note: API RP500 Supersedes prior editions RP 500A, B and C

API RP 540: Recommended Practice for Electrical Installations in Petroleum

Processing Plants.

API PSD 2216: Ignition Risk of Hot Surfaces in Open Air.

NFPA-70: Article 500: Hazardous (Classified Locations)

NFPA 30: Flammable and Combustible Liquids Code.

NFPA 321: Standard on Basic Classification of Flammable and Combustible Liquids.

NFPA 325: Fire Hazard Properties of Flammable Liquids, Gases and Volatile Solids.
 GENERAL ENGINEERING SPECIFICATION GES L.31
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NFPA 497A: Recommended Practice for Classification of Class I Hazardous
Locations for Electrical Installations in Chemical Process Areas.

NFPA 497M: Manual for Classification of Gases, Vapours and Dusts for Electrical
Equipment in Hazardous (Classified) Locations

3.2.3 IEC and Other Recommendations

When appropriate, Equivalent International Standards which may be used as alternatives are listed below
and may be used with the prior approval of the Owner. Equipment and materials complying with IEC
Recommendations shall be at least equal to the requirements of this specification.

BS 5345: Parts 1-8: Code of Practice for Selection, Installation and Maintenance of Electrical
Apparatus for use in Explosive Atmospheres.

BS 5501 Parts 1 to 9: Electrical Apparatus for Potentially Explosive Atmospheres.

IEC 79: Electrical Apparatus for Explosive Gas Atmospheres.

IEC 529: Classification of Degrees of Protection Provided by Enclosures

IP Part 1: Electrical Safety Code (1991)

IP Part 15: Area Classification (1990)

3.3 Principles of Hazard Reduction

The aim of regulations and standards for the use of electrical equipment and instruments in hazardous
areas is to ensure that the use of such equipment does not significantly increase the probability of loss of
life or property damage due to a fire or explosion. The method of hazard reduction is based on the fact
that for a fire or explosion to occur, both combustible material and a source of ignition must be
simultaneously present. If either is missing, or the probability of both occurring simultaneously is low,
then little or no hazard exists.

The probability of a source of ignition being present at a location depends on the design and operation of
the process plant. Plants are subdivided into areas in which the probability of combustible materials being
present is assessed using codes of practice issued, as a rule, by user bodies such as the American
Petroleum Institute, or the Institute of Petroleum (U.K.). This process is known as Area Classification.

3.4 Area Classification

3.4.1 General

Area Classification divides the plant into areas based on the probability of combustible material being
present in that area. Two systems of area classification predominate worldwide as follows:

3.4.2 North American System

In addition to the division based on the probability of hazardous vapours or gases being present, the North
American system specifies three classes of hazardous material:

Class I locations are those in which flammable gases or vapours may be present in the air in quantities
sufficient to produce an explosive or ignitible mixture.

Class II locations are those where combustible dusts, e.g. fine coke, may be present in sufficient quantity
to cause hazard.

Class III locations are those that are hazardous because of the presence of easily ignitible fibres or flyings,
 GENERAL ENGINEERING SPECIFICATION GES L.31
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e.g. textile mills, woodworking plants.

In addition to the hazardous material classification, the North American practice the sub-divides the
hazardous area into two Divisions. The divisions are defined by the National Electrical Code as follows:

Division 1

A Division 1 location is a location:

(a) in which ignitible concentrations of flammable gases or vapours can exist under normal operating
conditions, or;

(b) in which ignitible concentrations of such gases or vapours may exist frequently because of repair or
maintenance operations or because of leakage, or;

(c) in which breakdown or faulty operation of equipment or processes might release ignitible
concentrations of flammable gases or vapours, and might also cause simultaneous failure of electrical
equipment.

Division 2

A Division 2 location is a location:

(a) in which volatile flammable liquids or flammable gases are handled, processed, or used, but in which
the liquids, vapours or gases will normally be confined within closed containers or closed systems
from which they can escape only in case of accidental rupture or breakdown of such containers or
systems, or in case of abnormal operation of equipment, or;

(b) in which ignitible concentrations of gases or vapours are usually prevented by positive mechanical
ventilation and which might become hazardous through failure or abnormal operation of the
ventilating equipment, or;

(c) that is adjacent to a Division 1 location, and to which ignitible concentrations of gases or vapours
might occasionally be communicated unless such communication is prevented by adequate positive
pressure ventilation from a source of clean air, and effective safeguards against ventilation failure are
provided.

3.4.3 European System

The CENELEC/IEC system, which is normally applied in Europe and many other parts of the world
covers only hazards generated by gases, vapours and mists. The CENELEC/IEC system of area
classification subdivides the hazardous areas into three zones. The zones are defined by the IEC standard
IEC 79-10 as follows:

Zone 0: In which an explosive is continuously present or present for long periods.

Zone 1: In which an explosive gas-air mixture is likely to occur in normal operation.

Zone 2: In which an explosive gas-air mixture is not likely to occur, and if it occurs it will only exist
for a short period.

Note: Any area not covered by the above definitions is an un-classified area (sometimes referred to as
a non-hazardous or safe area).

3.4.4 Detail

With few exceptions, e.g. coking plants, areas in the oil and gas industries fall within Class I.
 GENERAL ENGINEERING SPECIFICATION GES L.31
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The most prominent of the national codes covering area classification include:

USA Article 500-503 of the National Electrical Code, NFPA 70 and API RP500.

U.K BS 5345, Part 2

Europe CENELEC 31

International IEC 79-10

Other bodies e.g. American Petroleum Institute (API RP 500 series), Instrument Society of America, (ISA
Series) and Institute of Petroleum (U.K.) give additional guidance for area classification in the Petroleum
Industry.

These systems do not attempt to quantify the probability of an explosive mixture being present, and
although the verbal definitions are similar, the application of the words to a specific industrial situation is
not standardised. In general, however, the equivalences of Division and Zone classifications and the
probability of an explosive mixture being present as given in "Table 1" below are accepted.

It should be noted that since Division 1 is the equivalent of Zone 0 and Zone 1, equipment suitable for use
in Zone 1 areas should not be used in Division 1 areas where the operating conditions are, or may be,
similar to those defined for Zone 0.

Table 1 - Zone Classifications

North America (NEC) International (IEC/Cenelec) & Probability of an Explosive

UK (BS 5345 Pt 2) Mixture Being Present
Div 1 Zone 0 > 10%

Div 1 Zone 1 > 1%

Div 2 Zone 2 > 0.1%

Safe Non-hazardous Nil

3.5 Gas (Material) Grouping (see Table 2)

3.5.1 Groupings

Gas grouping was introduced to reflect the difference in spark or flame energy required to ignite differing
types of gases or vapours i.e. gases within a gas group have similar explosion hazard properties.

Gas groupings are determined by the ease of ignition by electric sparks, the difficulty of containment of an
explosion within an explosion-proof enclosure, or by similarity of chemical structure. The materials in
each group are considered to present a hazard of the same general nature:

Group A Atmospheres containing acetylene

Group B Atmospheres such as hydrogen, containing more than 30% hydrogen by volume, or gases or
vapours of equivalent hazards e.g. butadiene, ethylene oxide, propylene oxide, and acrolein
(inhibited).

Group C Atmospheres such as hydrogen sulphide, ethylene, diethyl ether, carbon monoxide,
cyclopropane or gases of equivalent hazards.
 GENERAL ENGINEERING SPECIFICATION GES L.31
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Group D Atmospheres such as acetone, ammonia, benzene, butane, cyclopropane, ethanol, gasoline,
hexane, heptane, methanol, methane, natural gas, naphtha, propane, styrenes, octanes,
xylenes or gases of equivalent hazards.

3.5.2 U.S/European Systems

As with area classification, two systems have evolved i.e. that defined by North American standards and
that defined by IEC/CENELEC. Because the classification of gases and vapours are based not only on
chemical similarities but also on the results of tests carried out on apparatus which differ between the two
systems, precise comparisons cannot be made. In spite of these differences, however, there is good
agreement between the two groupings of materials.

The following Table 2 gives approximate equivalences of the two systems noting that Group I is reserved
in the IEC/CENELEC system for the underground mining activities. For IEC the gas grouping is
determined by flame path.

Table 2 - Gas Groupings

Test Gas North American IEC/Cenelec Ignition Energy

Grouping Grouping Microjoules
Propane (Methane) D IIA 180
Ethylene C IIB 60

Hydrogen B IIC 20

Acetylene A IIC 20

All standards for protected apparatus assume that any explosion will take place under normal conditions of
oxygen concentration, temperature, and pressure. If any of the factors, i.e. oxygen enrichment,
temperature or pressure are increased, then the ignition energy required to initiate an explosion decreases.
A careful engineering study, using all available assistance (Vendors/Contractors etc), is required in such
cases.

3.6 Temperature Classification

Flammable mixtures may be ignited by hot surfaces, and therefore all electrical equipment used in
hazardous atmospheres must be classified according to its maximum surface temperature. Where the
enclosure forms part of the protection, e.g. explosion proof, only the surface temperature of the enclosure
needs to be considered, but where the flammable atmosphere is deemed capable of penetrating the
enclosure e.g. Intrinsically Safe systems, the temperature of all components within the enclosure has to be
taken into account.

Internationally recognised temperature codes for the marking of electrical equipment for use in hazardous
areas are given in Table 3 below.

These codes assume an ambient temperature not exceeding 104°F (40°C). Where ambient temperatures in
excess of 104°F (40°C) are encountered, then its temperature classification should be reassessed and the
Vendor should confirm the suitability of the equipment for the application.
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Table 3 - Temperature Classification

Max Temp Max Temp N. American IEC/Cenelec

°°F °C Identification Identification
842 450 T1 T1

572 300 T2 T2
536 280 T2A -
500 260 T2B -

446 230 T2C -

419 215 T2D -
392 200 T3 T3
356 180 T3A -
329 165 T3B -

320 160 T3C -

275 135 T4 T4

248 120 T4A -

212 100 T5 T5

185 85 T6 T6

4.0 APPLICATION

The following is intended to provide basic guidelines for defining area classification for a particular
equipment item.

4.1 Introduction

The following procedure requires answering a series of questions. An affirmative answer to either
question in Paragraph 5.2 verifies the likely existence of a hazardous (classified) location. Boundaries of
locations may be determined by applying the recommendations of the preceding sections and referring to
appropriate figures in Sections A, B and C of API RP500, as applicable. Each equipment item, room,
section, or area should be considered individually in determining its classification. Initial planning should
focus on grouping of sources and allowing unclassified areas for electrical equipment installations, as far
as possible..

Determinations of classification will require consultation with process and project engineers, facility
design engineers, fire and safety specialists, instrument engineers, and electrical engineers and the
recorded agreement of all parties involved.

This aspect shall be formalised using the 'LEAC' Form(s) (NFPA or BS as relevant) in Section 10.0.
 GENERAL ENGINEERING SPECIFICATION GES L.31
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4.2 Step 1 - Need for Classification

The need for classification of a location is indicated by an affirmative answer to either of the following
two questions:

1. Are flammable liquids, gases, or vapours handled, processed or stored in or adjacent to the area?

2. Are combustible liquids likely to be handled, processed, or stored in or adjacent to the area at
temperatures above their flash points?

4.3 Step 2 - Assignment of Classification

Assuming an affirmative answer from Step 1 and noting the need to apply Class I, II or III according to the
source of hazard, the questions below should be answered to determine the degree of classification
(Division 1, Division 2 or Unclassified).

4.3.1 Division 1 locations normally are dictated by an affirmative answer to any one of the questions that
follow:

1. Is an ignitible atmospheric concentration of gas or vapour likely to exist in the location under normal
operating conditions?

2. Is an ignitible atmospheric concentration of gas or vapour likely to occur in the location frequently
because of maintenance, repairs, or leakage?

3. Would a failure of process, storage, transfer or similar equipment likely cause an electrical system
failure that would create an ignition source (e.g. arcing) simultaneously with the release of ignitible
concentrations of gas or vapour?

4. Is flammable liquid or gas handled, processed or stored in an inadequately ventilated location?

5. For flammable liquids with heavier-than-air vapours, is ventilation inadequate to ventilate all areas
(particularly floor areas) where flammable vapours might collect?

6. For lighter-than-air gases, are roof or wall openings inadequately arranged to ventilate all areas
(particularly ceiling areas) where gases might collect?

4.3.2 After Division 1 locations have been determined, Division 2 locations usually may be distinguished by an
affirmative answer to any one of the following questions:

1. In a system containing flammable liquids or gases in an adequately ventilated location. Can the
liquid or gas escape from potential sources (such as valve packing, flanges, or pump seals) as a result
of an abnormal condition?

2. Is the location adjacent to a Division 1 location without separation by vapour-tight walls or barriers?

NOTE: In some cases communications of flammable gases or vapours between adjacent locations
can be prevented by adequate positive-pressure ventilation from a source of clean air.

3. If positive mechanical ventilation is provided, could failure or abnormal operation of the ventilating
equipment permit ignitible concentrations of gas or vapour to enter or accumulate in the location?

4.4 Step 3 - Extent of Classified Locations

Reference Paragraph 4.7 and Section 5 of API RP500. Reference also Sections A, B or C, as applicable.
 GENERAL ENGINEERING SPECIFICATION GES L.31
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4.5 Step 4 - Determination of Group

Reference Paragraph 3.5 of API RP500 to determine the proper group.

The Hazardous Area Classification Form shall be utilised in following these steps to record the reasons for
the philosophy adopted for classifying various items of equipment or areas of plant.

Copies of these forms are included at the end of this specification,, one copy for projects covered by the
U.S. - NFPA codes and one for the British BS 5345 Codes.

4.6 Documentation

It is necessary that area classifications be documented. Electrical area classification drawings together
with the hazardous area classification forms are used as a guide by designers, constructors, and inspectors
of electrical installations, and all classified locations should be indicated. This documentation will serve as
a record of the original classifications and as a guide when future additions or revisions are considered.

5.0 EQUIPMENT AND PIPING

5.1 Introduction

To provide a basis for assessing the extent of classified areas, studies have been made of the ways in
which release of flammable gases, vapours and liquids can be expected to occur during operation of
equipment handling such materials. Methods have been developed for calculating the size of gas or
vapour clouds so formed and the distances necessary for their dispersal and dilution with air, in well-
ventilated situations, to below their lower flammable limit. The object has been to establish a physical
model of the escape from each source of hazard and to use it to derive figures for the extent of Division

1 and 2 either from practical observations and/or calculations or, in the limit, on the basis of personal
judgement.

The following notes are given in explanation for the non specialist engineer to understand the basis of
producing Hazardous Area Drawings. In general, the distances used in the API RP500 figures should be
utilised.

Hazardous Area Classification Forms are included at the end of this specification.

5.2 Leakage from Pumps

Refer to API RP 500 Figures B.18a to B.18d for the vertical and horizontal affected areas.

The packing of a pump gland and the faces of a mechanical seal are wetted with the liquid handled and as
a result there may be some escape of liquid or vapour to atmosphere. Mechanical seals offer advantages
over packed glands on the grounds of both reduced leakage and reduced maintenance cost and are
accordingly to be preferred, particularly for pumps handling hot flammable liquids or liquefied flammable
gases.

In the case of a pump handling a flammable liquid below its atmospheric pressure boiling point, the
amount of liquid which escapes to atmosphere in normal operation is generally very small, and the extent
of vaporisation of the liquid which escapes is also very small. The extent of the hazardous area around
either the packed gland or the mechanical seal is too limited to be of practical significance for area
classification. There is no significant Division (Zone) 1 around a pump handling a flammable liquid below
its atmospheric pressure boiling point.

With a pump handling either a flammable liquid at or above its atmospheric pressure boiling point or a
liquefied flammable gas it is assumed that a mechanical seal will be used. In these cases, a local
 GENERAL ENGINEERING SPECIFICATION GES L.31
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hazardous area may exist in normal operation in the immediate vicinity of the seal. Therefore it is
prudent to have a local Division (Zone) 1 (in most cases a sphere of 1ft (300mm) radius) around a
mechanical seal of a pump handling either a flammable liquid at or above its atmospheric pressure boiling
point or a liquefied flammable gas.

Deterioration of the gland packing or failure of the seal in service gives rise to increased leakage. The
extent of vaporisation of flammable liquid below its atmospheric pressure boiling point is still very small
but the liquid is likely to splash over the pump assembly and surrounding ground. This causes a
flammable atmosphere in the vicinity of the area so-wetted. The extent of the hazardous area is estimated
to be, as a maximum, 10ft (3 metres) beyond the edge of the wetted area. This area is Division (Zone) 2
since the gland deterioration or seal failure is an abnormal occurrence.

In the case either of flammable liquids handled at temperatures above their atmospheric pressure boiling
point or of liquefied flammable gases the increased leakage due to seal failure necessitates an increase in
the extent of the area classified by the provision of a Division (Zone) 2 outside the areas already classified
Division (Zone) 1.

The worst leakage results from a complete failure which allows the material handled to escape freely
through the gap between the pump shaft and the neck ring of the stuffing box in the case of a packed
gland, or between the pump shaft and the stationary seat in the case of a mechanical seal. As already
stated, it is preferable to use a mechanical seal with all flammable liquids and liquefied flammable gases.

The above discussion relates to pumps with single packed glands or single mechanical seals and does not
cover special cases such as, for example, a pump with double mechanical seals and a buffer liquid sealant
between the seals. In such a case, if means are provided to detect failure of the inner seal, the assessment
of the hazardous area should be related to the escape of the buffer liquid through the outer seal.

5.3 Leakage from Compressors

Refer to API RP 500, figures B.18a to B.18d and C.14, 15 and 16.

Gas leaks out through the glands and the valve-pocket cover-joints during normal operation of a
reciprocating compressor, and there is an escape for a short period every time the snubber vessel and
interstage cooler drains are operated, all of these releases giving rise to a local Division (Zone) 1. The
quantity of gland leakage in normal operation is, however, small, particularly if the gland is vented via a
lantern ring and the distance-piece between the cylinder and the crankcase is enclosed and vented to a safe
place outside the compressor-house. The leakage from the valve-pocket cover joints is also small and the
Division (Zone) 1 required to cater for both these leakages is therefore only a nominal one. A distance of
2ft (600mm) all round the cylinders is proposed. The snubber (buffer) and interstage cooler drains are
used to run-off accumulations of liquid, either into an open tundish device to the oil/water drain or via a
knock-out pot vented to a safe place. With the open discharge the amount of gas escaping in normal
operation is small, since the drain is closed as soon as all the liquid has run-off and gas appears, and a
Division (Zone) 1, of 2ft (600mm) all round the drain discharge is considered to be adequate.

In the case of centrifugal compressors the shaft sealing arrangement usually takes the form of two seals of
either the carbon ring face-contact type or the floating-bush close-clearance type, the space between the
seals being supplied with oil under pressure. Irrespective of the type of seal some oil leaks inwards into
the machine and outwards to the atmosphere. The former leakage, which becomes contaminated with
process gas, drains into a pot at the machine from which the gas released by the depressurising of the oil is
vented to a safe place outside the building whilst the oil is discharged to drain or to a recovery system.

There is no leakage from the seal itself during normal operation but, to cover oil-vapour emission from
breathers on the bearing housings, leakage from gas reference pressure piping joints, etc; a Division (Zone)
1 2ft (600mm) all round the seal is proposed. Since it is necessary to remove the cover of the
contaminated seal oil pot to examine the discharge from traps during sampling of the sour oil and when
checking the leakage rate, all of which are routine operations, a further Division (Zone) 1 is proposed 1m
round the seal oil pots and open drains.
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Under abnormal conditions, such as rapid deterioration of a gland or failure of seal, a much larger quantity
of gas may be released into the compressor house atmosphere.

Hydrogen-rich gases and fuel gases are generally lighter than air and tend to rise, but recent studies of air
movement in plant compressor-houses have shown that velocities are often too low to promote turbulent
diffusion of the gas in the surrounding atmosphere. The only effective means of dispersal of the gas is
then bodily-displacement with air through the compressor house roof ventilators, the driving force for
which is supplied by the heat dissipated from the machinery. Under these conditions the whole space
under the compressor-house roof is classified Division (Zone) 2 together with further spaces around the
roof-ventilators and outside the line of the open walls of the compressor-house floor, giving rise to a
Division (Zone) 2 the extent of which is discussed below.

5.4 Leakage from Flanges and Joints

The size of a joint leak depends on the type of joint face and gasket used. Thus with a flanged joint using
a compressed fibre (CAF) gasket the blow-out of a section of gasket between adjacent bolts is always a
possibility. If the simple gasket is replaced by a metal-clad or spirally supported gasket with backing ring,
or a joint is used with a trapped gasket or ring, a blow-out is virtually impossible and the orifice through
which a leak can occur is reduced to about one tenth of the cross-sectional area possible with a simple
joint and gasket). In many situations the hazardous area arising from a joint leak of this size is
insignificant in comparison with other likely leakage.

Joints which are subjected to sharp changes in temperature are the most likely ones to leak. It may
however be countered by the use of trapped or solid metal ring gaskets with, in severe cases, extended
bolts and sleeves. In general, with suitably-designed equipment, joints will leak only under abnormal
conditions and hence only Division 2 classification is required.

A leak of a flammable liquid below its atmospheric pressure boiling point gives rise to a flammable
atmosphere in the vicinity of the liquid surface only, but the escape through a joint gasket
blow-out is as a jet which travels some distance away from the source (unless the joint is
shrouded) and there is some scattering of the liquid as it falls to the ground, spreading the
hazard under the path of the jet. In practice, therefore, the whole area under the trajectory of
the jet in all possible directions of travel should be classified. The area is a narrow strip
fanning out on either side of a joint located in a vertical plane, and extending all round a joint
located in a horizontal plane. This applies irrespective of the height of the joint above the
ground, but will be accentuated in the case of a joint in an elevated position. At ground level
the area may be further extended by spread of the liquid over the ground. When the liquid
leaking is at a temperature above its atmospheric pressure boiling point, giving a partial
flash-off vapour on release of pressure, the residual liquid still falls to the ground as a jet in
the manner described above, but the area classified should also allow for the safe dispersal of
the vapour. In the case of liquefied flammable gases the residual liquid is cold and it does
not precipitate but vaporises in the cloud of flash vapour as it picks up heat from the
surroundings. The classified area is therefore that required for the safe dispersal of the total
material as vapour.

A leak of flashing liquid or liquefied flammable gas, and also the horizontal distance required for dispersal
to the lower flammable limit of the vapour when it is released at or near ground level, are treated as the
case of a leak of these materials from a pump gland or seal (Refer to Section 6.2 above).

For a leak of flashing liquid from a joint in an elevated position the horizontal extent of the Division 2 is
only 70% of that for the same leak at or near ground level since the vapour diffuses more quickly at a
height above ground than at ground level.

The escape of a liquefied flammable gas through a joint gasket blow-out is as a jet of vapour with
entrained liquid droplets, with sufficient velocity to promote jet-mixing with the surrounding air. When
the escape is at or near ground level the jet is likely to meet obstructions which dissipate its kinetic energy;
 GENERAL ENGINEERING SPECIFICATION GES L.31
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dilution of the vapour then occurs only by diffusion in the surrounding air. An escape from a joint in an
elevated position is much less likely to hit an obstruction and dilution by jet-mixing, resulting in a smaller
horizontal distance, can be assumed.

An escape of gas through a joint leak will be at sonic velocity and the rate of escape can be calculated as
already described for leakage from compressors. (See Section 5.3 above).

5.5 Leakage from Valve Glands

Leakage of liquid hydrocarbons from a valve gland on a well-laid-out plant drips on to paving which is
graded to an access point into the sealed drainage system. At or near ambient temperature a flammable
atmosphere exists only close to the liquid surface and the classified area is below the leaking valve and in
the immediate vicinity of the wetted area of paving. Whether the classification is Division (Zone) 1 or 2
depends upon the frequency of the leakage and the number of valves installed in close proximity to each
other.

It is considered unlikely that leakage of gas from a valve gland will be large enough to justify more than a
nominal classified area - say a sphere of radius 3ft (1 metre). Again the frequency of leakage and number
of valves in close proximity determine whether the classification is Division (Zone) 1 or 2.

5.6 Relief Valve Discharge to Atmosphere

Refer to API 500 Figure B.15.

Discharge direct to atmosphere must be carried out so that the material is diluted to below its lower
flammable limit in air before it reaches a source of ignition, and to its threshold limit value of toxicity
before it reaches ground level or a working platform above ground level. The first of these two conditions
is particularly relevant to area classification although the second may also have some bearing on the
positioning of electrical equipment from the point of view of maintenance work.

Gases lighter than air may in general be discharged from a point above plant buildings and structures and
be allowed to disperse by diffusion in the atmosphere. With gases of very high hydrogen content it is
preferable to discharge them at high velocity (to overcome back-diffusion of air into the vent stack); the
gases are then diluted with air entrained by jet-mixing.

A discharge from a relief valve, or an emergency blow-off of a gas or vapour heavier than air, may only be
put direct to atmosphere at a velocity which is sufficient to ensure dilution to below the lower flammable
limit with air entrained by jet-mixing. If this condition cannot be met the discharge should be put to a
closed flare system.

In general, a relief valve will discharge only under abnormal conditions and the classification round the
point of discharge to atmosphere is Division (Zone) 2, although to allow for small leakages past the valve
Division (Zone) 1 is proposed for 3ft (1 metre) around the discharge pipe tip. If, however, because of a
special process feature, a particular relief valve is expected to discharge frequently to atmosphere the
whole classification may become Division (Zone) 1. The extent of the classified area round the point of
discharge to atmosphere from a relief valve or an emergency blow-off is, in general, the area required for
dilution to the lower flammable limit by air entrained by jet-mixing.

5.7 Venting of Small Quantities of Gas (except Tanks)

Section 6.6 above relates to relief valves and emergency blow-offs through which relatively large
quantities of process materials are released. With small quantities of gases and vapours, such as escape
from a lantern ring in a compressor gland or from a sealed drain, venting to atmosphere from a point
above plant structures and buildings where there is free air movement is acceptable. These escapes occur
in normal operation, and so give rise to either Division (Zone) 1 or Division (Zone) 0, taken as a sphere (to
cover materials both heavier and lighter than air) round the point of discharge. Since the quantities of
materials are small, the classified area need not extend very far and a Division (Zone) 1 of radius 5ft (1.5
 GENERAL ENGINEERING SPECIFICATION GES L.31
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metres) is proposed. Occasionally the discharge may increase for a limited period and, to cover this
contingency, a further 5ft (1.5 metres) outside the Division (Zone) 1 should be classified Division (Zone) 2.

5.8 Process Drains and Sample Points

The classification of the area round a drain-point discharge to atmosphere depends upon the nature of the
material drained and whether the drain is used regularly during process operations or only when preparing
plant for maintenance work.

A process drain provided to draw off water collected as a bottom layer below hydrocarbon should be
operated so as to remove as much water as possible without losing an appreciable amount of hydrocarbon.
In normal operation, therefore, the operator will shut the drain valve as soon as he observes hydrocarbon
in the water stream, but since some hydrocarbon does escape an area immediately round the discharge
point should be classified Division (Zone) 1. If the operator fails to shut the drain valve at the right time,
hydrocarbon may be discharged continuously, and the hazardous area round the drain point thereby
increased, but this should occur only under abnormal circumstances in which case the additional
hazardous area should be classified Division (Zone) 2.

Drainage of water is usually carried out at near ambient temperature and if the hydrocarbon is a liquid
under ambient conditions the amount of vapour generated from an escape through the drain point is small,
and in normal operation there is no significant flammable atmosphere round the drain point.

If the hydrocarbon is a liquefied flammable gas, vapour will be generated by adiabatic flash-off and then
by evaporation of the remaining cold liquid. The escape from a drain line is as flashing flow giving an
effluent of vapour containing droplets of liquid. The rate of escape and the resultant Division (Zone) 2
have been calculated on the same basis as for a liquefied flammable gas sample point. The extent of the
Division (Zone) 1 around the drain-point has been calculated on the basis of turbulent diffusion of the
vapour cloud from an instantaneous release of liquefied flammable gas.

A drain point which is used only infrequently (eg once a year) for the purpose of preparing equipment for
maintenance work will give rise only to a Division (Zone) 2.

Sampling of liquids into an open can should be carried out at a temperature which is low enough to ensure
no loss of "light ends" from the sample, and a tundish should be provided below the sample-point to
collect purgings from the sample line for delivery into a sealed drain or a closed container. There should
thus be no spillage and negligible escape of vapour. Only under abnormal circumstances (eg insufficient
cooling of the sample) will there be a significant flammable atmosphere; hence only Division (Zone) 2
classification is required. The extent of the Division (Zone) 2 is estimated as 5ft (1.5 metres) all round the
sample-point.

5.9 Fixed Roof Tank Vent

Refer to API 500 Figures A.4, B.11a and B.11b.

Discharge of vapour to atmosphere from the vent of a fixed-roof tank containing a flammable liquid
occurs every time a movement is made into the tank and at other times during normal operation when it is
necessary to relieve the tank pressure. The vapour is discharged as a mixture with the air (or the inert
blanketing gas) present in the tank atmosphere, but the mixture is about three times heavier than air and
tends to flow down over the top and side of the tank and then spread across the ground adjacent to the
tank. The vapour concentration may be initially above the upper flammable limit, but it soon becomes
within the flammable range as the vent discharge mixes with air outside the tank and remains so until
further dilution with air reduces it to the lower flammable limit.

The flow of vapour from the vent gives rise to a hazardous area which clearly should be classified
Division (Zone) 1 immediately next to the tank and across the adjoining ground as far as the vapour-air
mixture remains flammable. For the dispersal of discharges from a gasoline storage tank vent the extent of
the hazardous area immediately adjacent to a tank is proposed as 10ft (3 metres) all round the roof and
 GENERAL ENGINEERING SPECIFICATION GES L.31
AREA CLASSIFICATION Page 22 of 26
Rev 0 1999
shell, and the maximum horizontal extent of the hazardous area at ground level, ignoring any effect of a
bund wall, is proposed as 50 ft (15 metres) from the tank.

Once the vapour has reached the ground, however, it is inside the bunded volume round the tank in which
it can accumulate up to the height of the bund wall. It is doubtful whether the vapour from a vent
discharge can actually escape over the bund wall in flammable concentrations except when the wall is 10ft
(3 metres) or less from the tank. In many cases, therefore, it is sensible to take the bund wall as the
horizontal boundary of the hazardous area rather than a point 50ft (15 metres) from the tank. The total
Division (Zone) 1 is then 10ft (3 metres) all round the roof and shell together with the rest of the bund
volume up to the height of the bund wall.

In the event of a large spillage of flammable liquid into the tank compound, such as could result from
gross overfilling, vapour-air mixture may fill the bund volume and overflow the wall in flammable
concentration. To cover this contingency, which can be expected to arise only under abnormal conditions,
the area within a horizontal distance of 15ft (3 metres) beyond the bund wall, or within a distance of 15ft
(5 metres) from the tank side (whichever results in the greater area), and to a height of 15ft (5 metres)
above ground level should be classified Division (Zone) 2.

For a liquid with a flash point 90°F (32°C) and above area classification of a storage installation is
required only when the storage temperature is above the flash point and in such cases the same
classification as for a liquid with a lower flash point is proposed.

5.10 Floating Roof Tank Seals

Refer to API 500 Figure C.7.

The statements in 6.9 above apply equally to storage in floating-roof tanks.

Leakage from the seal between a floating roof and the tank shell occurs during normal operation and,
although the quantity of vapour escaping is expected to be relatively small, a flammable mixture with air is
likely to be present in the partially-enclosed space above the floating roof up to the top of the tank wall.

This space should therefore be classified Division (Zone) 1. If the leakage becomes abnormally high due
to deterioration of the seal, vapour in the flammable range may spill over the top of the tank wall. On this
basis the area immediately above and round the tank wall and also the bund area (which are classified
Division (Zone) 1 for fixed-roof tanks) become Division (Zone) 2 for floating-roof tanks. It is, however,
desirable to restrict electrical apparatus inside the bund and it may be preferable, therefore, to retain a
Division (Zone) 1 classification.

5.11 Loading Operations

Refer to API 500 Figures A.11 to A.14 and C.17 to C.21.

The loading of gasoline or other liquids of similar volatility into a road or rail tank wagon displaces
through the filling-hatch a mixture of vapour and air. The volume flow when filling a tank wagon, is
much lower than that when filling a tank so that the volume of vapour to and the distance within which the
concentration is reduced to the lower flammable limit by diffusion in the atmosphere are also smaller.

There is commonly weather-protection over a tanker-filling bay in the form of a roof and vertical sides
extending part of the way to ground level. To allow for abnormal rates of vapour escape, the space under
the roof and also areas that are 5 ft (1.5 metres) outside the Division (Zone) 1 round the top and sides of
the tank and 25ft (7.5 metres) beyond the Division (Zone) 1 limit along the ground to a height of 10ft (3
metres) above ground level should be classified Division (Zone) 2.

Loading and off-loading of liquefied flammable gases is done through closed pipe systems and the
material left in flexes at the end of a movement is either vented to a safe place, displaced back to storage
 GENERAL ENGINEERING SPECIFICATION GES L.31
AREA CLASSIFICATION Page 23 of 26
Rev 0 1999
by the use of inert gas, or contained by means of self-sealing couplings. In normal operation, therefore,
escape of the gas to atmosphere in the vicinity of the loading operation is either non-existent or small in
quantity. In view of the volatility of the material, a nominal Division (Zone) 1 is recommended for a liquid
tanker installation.

5.12 Vapour from an Oil/Water Separator

Refer to API 500 Figure A.8

The oil collected in the sealed drainage system of a plant area and then discharged to an oil/water separator
generally covers the whole range of volatility of materials handled on the plant. However, the oil is
normally not rich in light constituents since most of the light constituents escape through the vents of the
drainage system. The oil on the water is still flammable, the separator area and the area immediately
round it to a distance of 25ft (7.5 metres) and to a height of 3ft (1 metre) above ground level should be
Division (Zone) 1.

Exceptionally there can be a large spillage of light material although this should only occur as the result of
some abnormal occurrence on the plant. To cover this contingency an area to a horizontal distance of 75ft
(23 metres) and to a total height of 10ft (3 metres) should be Division (Zone) 2.

The extent quoted are related to a typical oil/water separator dealing with spillage of a variety of materials
from a plant area. Smaller distances may apply to a small separator dealing with a single material of
known composition.

6.0 NEMA/IEC DIFFERENCES

6.1 General

This specification is primarily written for procedures in accordance with the American (NEMA)
Standards.

If it is necessary or advantageous to follow procedures in accordance with International (IEC) Standards,

the specification can still be utilised but the salient differences occurring should be noted as detailed
below.

6.2 Salient Differences

This section does not attempt to list every difference between American (NEMA) standards and IEC
standards, but covers only those salient differences that could affect the final installation if not properly
addressed during the design phase of a contract.

6.2.1 Units - SI Units

The NEMA Standards in many cases utilise imperial units (feet, pounds, degrees fahrenheit, etc), whilst
the IEC Standards utilise SI units (metres, kilogrammes, degrees celsius etc).

For electrical equipment, the (American) Institute of Electrical and Electronic Engineers (IEEE) have
recommended that the use of the Imperial (British-American) units be reduced as rapidly as possible in
favour of the SI units, with certain implementations such as the use of horsepower being phased out first.

6.2.2 Ingress Protection IEC 529

The IEC Code precisely defines the ingress protection offered to the machine by its enclosure against solid
bodies and moisture. The NEMA Code MGI-Part 5, is now similar, and for most refinery installations,
and enclosure of "IP54" (as defined in both codes) should be adequate for most installations.
 GENERAL ENGINEERING SPECIFICATION GES L.31
AREA CLASSIFICATION Page 24 of 26
Rev 0 1999
6.2.3 Hazardous (Classified) Areas

If it is intended to purchase a machine to IEC Standards, reference shall be made to the contract hazardous
area drawing produced and the principles stated in GES L.35, to establish the enclosure type needed.

The National Electrical Code NFPA 70, Article 500 and API RP500 cover the American approach to
hazardous (Classified) areas in some detail.

6.2.4 International Comparison of Zones

This subject is covered in Section 3.4.

6.2.5 Gas Groupings and Temperature Classification

This subject is covered in Section 3.5.

7.0 LIST OF EQUIPMENT FOR AREA CLASSIFICATION (LEAC) - SUB-INDEX

7.1 'LEAC' based on BS 5345

7.2 'LEAC' based on NFPA

 LIST OF EQUIPMENT FOR AREA CLASSIFICATION (LEAC)
(BS 5345)
CLIENT P.O. / CONTRACT NO. SHEET NO.

PLANT LOCATION DRAWING NO.

EQUIP. NO. EQUIPMENT TITLE EQUIP. PROCESS TEMP. & DESCRIPTION SOURCE OF HORIZ. DIST. PERMITTED ELECTRICAL EQUIPMENT COMMENTS
LOCATION MATERIALS PRESS. OF PROCESS HAZARD FROM SOURCE
HANDLED MATERIAL TO EQUIPMENT BS PART NO./ BS PART NO./TYPE OF PROTECTION (TICK BOX)
CONTAINMENT ZONE !/ ZONE 2/ DATA
(VENTS, SEALS, ZONE 2 NON-HAZ 1 1 3 4 5 6 7 8
DRAINS, ETC.) BOUNDARY BOUNDARY SURF. APP'TUS Ex(d) Ex(1a&1B) Ex(p) Ex(e) Ex(N) Ex
TEMP. GROUP (s,o,q)-m
CLASS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

COLS. 1 TO 6 BY PROJECT (INC. PROCESS) COLS. 8&9 VERTICAL DISTANCES SET WHEN AREA CLASSIFICATION DWG. PRODUCED. REVISION NO./DATE 0

COLS. 7 TO 9 BY HAZARDOUS AREA DRAWING COMMITTEE COL. 17 ENCAPSULATION-TYPE PROTECTION "m" COVERED BY BS 5501 PART 8 PREPARED BY/ DATE

COLS. 10-17 BY ELECTRICAL GROUP AUTHORISED BY/DATE

COL. 18 AS REQUIRED PURPOSE

S:\l-series\l-31\Dl3101r0.xls
 LIST OF EQUIPMENT FOR AREA CLASSIFICATION (LEAC)
(US - NFPA)
CLIENT P.O. / CONTRACT NO. SHEET NO.

PLANT LOCATION DRAWING NO.

EQUIP. NO. EQUIPMENT TITLE EQUIP. PROCESS TEMP. & DESCRIPTION SOURCE OF HORIZ. DIST. PERMITTED ELECTRICAL EQUIPMENT CLASS COMMENTS
LOCATION MATERIALS PRESS. OF PROCESS HAZARD FROM SOURCE
HANDLED MATERIAL TO EQUIPMENT NFPA 497M API RP500 (SECS. A, B, C) NFPA 70 ARTICLE 501
CONTAINMENT DIV. !/ DIV. 2/ (TICK BOX) (TICK BOX)
(VENTS, SEALS, DIV. 2 UNCLASS. SURF. GAS DIV.1 DIV.2 UNCLASS. DIV.1/ PURGED INTRINS.
DRAINS, ETC.) BOUNDARY BOUNDARY TEMP. GROUP DIV.2 SAFE
I.D. NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

COLS. 1 TO 6 BY PROJECT (INC. PROCESS) COLS. 8&9 VERTICAL DISTANCES SET WHEN AREA CLASSIFICATION DWG. PRODUCED. REVISION NO./DATE 0

COLS. 7 TO 9 BY HAZARDOUS AREA DRAWING COMMITTEE PREPARED BY/ DATE

COLS. 10-17 BY ELECTRICAL GROUP AUTHORISED BY/DATE

COL. 18 AS REQUIRED PURPOSE

S:\l-series\l-31\Dl3102r0.xls
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES P.02

PLANT PIPING SYSTEMS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 2 of 39
Rev 0 1999

INDEX

SECTION TITLE PAGE

1.0 SCOPE OF SPECIFICATION 6

1.1 Introduction 6

1.2 Other NOC Specifications 6

2.0 DEFINITIONS 6

2.1 Technical 6
2.2 Contractual 8

3.0 DESIGN 8

3.1 Codes and Standards 8

3.2 Plant Piping Arrangement 9
3.3 Design Pressure and Temperature 9
3.4 Line Sizing 10
3.5 Location of Piping 11

4.0 PIPING EXPANSION AND FLEXIBILITY 11

4.1 General 11
4.2 Stress Calculations 12
4.3 System Flexibility 12
4.4 Expansion Joints 12
4.5 Spring Hangers and Supports 12
4.6 Allowable Loads at Equipment 13
4.7 Anchors and Restraints 13

5.0 PIPE SUPPORTS 13

5.1 General 13
5.2 Support Spacing 13
5.3 Supporting of Small Bore Piping 14
5.4 Tower or Column Pipe Supports 14
5.5 Guide Spacing 14
5.6 Standard Pipe Supports 15
5.7 Components for Standard Pipe Supports 15
5.8 Special Pipe Supports 15

6.0 PIPE SPACING 16

6.1 General 16

7.0 SMALL BORE PIPING 16

7.1 Location of Branches 16

7.2 Routing 16
 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 3 of 39
Rev 0 1999

SECTION TITLE PAGE

8.0 STEAM PIPING 16

8.1 General 16
8.2 Condensate Collection 17
8.3 Steam Traps 17

9.0 PIPE, FITTINGS AND FLANGES 18

9.1 General 18
9.2 Changes of Direction 18
9.3 Line Reduction 18
9.4 End Closures 18
9.5 Threaded Connections 18
9.6 Elevation from Grade 18
9.7 Installation of Flanges 18

10.0 PRESSURE BLINDS AND SPACERS 18

10.1 General 18
10.2 Installation 19
10.3 Spectacle Blinds 19
10.4 Jack Screws 19

11.0 VALVES 19

11.1 General 19
11.2 Valve Access Requirements 19
11.3 Chain Operators 20
11.4 Gear Operators 20
11.5 Full Port Valves 20
11.6 Valves In Steam Service 20
11.7 Valves In Hydrogen Service 20
11.8 Bleed Valves 21
11.9 Valve Stem Extensions 21

12.0 HEAT EXCHANGERS PIPING 21

12.1 General 21
12.2 Design 21
12.3 Reboilers 21
12.4 Vents and Drains 22
 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 4 of 39
Rev 0 1999

SECTION TITLE PAGE

13.0 PUMPS, COMPRESSORS AND TURBINES 22

13.1 General 22
13.2 Pump Piping 22
13.3 Compressor Piping 23
13.4 Steam Turbine Piping 24

14.0 TOWERS AND DRUMS 25

14.1 Piping Design 25

15.0 FIRED HEATERS AND BOILERS 25

15.1 General 25
15.2 Operating Access 25
15.3 Fuel Oil Piping 25
15.4 Fuel Gas Piping 26
15.5 Atomising Air 26
15.6 Atomising Steam 26
15.7 Snuffing and Purge Steam 26
15.8 Boiler Piping 27
15.9 Sootblower Steam Piping 27

16.0 STORAGE TANKS 27

16.1 Atmospheric Storage 27

16.2 Pressurized Storage (Excluding Refrigerated Storage) 28

17.0 VENTS AND DRAINS 28

18.0 SAMPLE CONNECTIONS 28

18.1 General 28
18.2 Location 28
18.3 Gas Samples 29
18.4 Liquid Samples 29
18.5 Sample Cooler 29

19.0 INSTRUMENT CONNECTIONS 29

19.1 General 29
19.2 Location 29
19.3 Temperature Connections 29
19.4 Pressure Connections 30
19.5 Flow Instruments 30
19.6 Level Instruments 30
19.7 Control Valves 31

SECTION TITLE PAGE

 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 5 of 39
Rev 0 1999

20.0 RELIEF AND BLOWDOWN SYSTEMS 31

20.1 Design 31
20.2 Pressure Safety Relief Valves 32

21.0 COOLING SYSTEMS 33

21.1 Air Fin Coolers 33

21.2 Cooling Water Supply and Return 33

22.0 UTILITY STATIONS 33

22.1 General 33
22.2 Design 33

SKETCHES

Figure No 1 - Rational Solution of Pressure Drop for Liquids35

Figure No 2 - Formal Stress Analyses Requirements 36
Figure No 3 - Guide Spacing 37
Figure No 4 - Line Spacing Table in Inches 38
Figure No 5 - Line Spacing Table in Millimetres 39
 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 6 of 39
Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

This specification covers the general requirements for the mechanical design of plant piping systems.

1.1.1 This specification applies to plant piping systems for refineries, onshore oil and gas installations and
processing facilities.

1.1.2 This specification does not cover piping systems for process fluids in cryogenic service, or in any service
that does not fall within normal refinery, onshore oil or gas categories.

1.1.3 Pipeline systems are outside the scope of this specification and are provided for in GES R.02 "Pipeline
Systems".

1.1.4 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exceptions must be authorised in writing by the Owner.

1.1.5 In the event of any conflict between this specification and the data sheets, or with any of the applicable
codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification before proceeding with the work.

1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES A.01 - Plant Layout and Spacing

GES H.04 - Fire Water System

GES P.01 - Piping Material Specification

GES P.07 - Underground Piping

GES P.09 - Steel Piping Fabrication (Shop or Field)

GES P.10 - Erection and Testing of Steel Piping

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Anchor

A welded or clamped attachment to a pipe, that prevents movement of the pipe in any direction.

Design Pressure

The piping system shall be designed for a design pressure which shall meet the requirements of ASME
 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 7 of 39
Rev 0 1999
B31.3 301.2. For guidance, unless specified otherwise by the Vendor/Contractor and agreed by the Owner,
the design pressure shall be the maximum pressure encountered in normal or upset conditions, subject to a
margin of 10% or 25psi (172kPa), whichever is the greater. The design pressure shall be at least equal to
the setting of any relief valve protecting the system.

Design Temperature

The piping system shall be designed for a maximum and/or minimum temperature which shall meet the
requirements of ASME B31.3 301.3. For guidance, unless specified otherwise by the Vendor/Contractor
and agreed by the Owner, the design temperature shall be calculated according to the following:
The maximum and/or minimum operating temperatures encountered in normal or upset conditions shall be
subject to the following margin:

Operating Temperature Condition Design Factor

At or below -20°F (-29°C) Minimum Deduct 18°F

Temperature (10°C)

Above -20°F (-29°C) Minimum Deduct 27°F

Temperature (15°C)

Maximum Condition Maximum Add 27°F

Temperature (15°C)

Expansion Joints

A mechanical device used for absorbing longitudinal expansion and contraction in a piping system.

Guide

A welded or loose clamped device that allows movement of the pipe along the longitudinal axis of a pipe,
but prevents lateral distortion or movement.

Restraint

A welded or clamped attachment to a pipe, that prevents movement of the pipe in one
direction, but allows movement in another direction.

NPS

Nominal pipe size in inches.

Small Bore Piping

Piping that is NPS 1½ and smaller. Piping of this size normally has socket weld or screwed fittings and
valves.

Spring Supports

A mechanical device that both supports a pipe and absorbs vertical displacement by means of a helical coil
spring.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 8 of 39
Rev 0 1999

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the piping system.

Vendor

The Company supplying the equipment.

Contractor

The main Contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by the contractor, to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the Piping System has
been designed, fabricated, inspected and tested in accordance with the requirements of this specification
and Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or assigned Inspection Authority, who
verifies that the piping system has been designed, fabricated, inspected and tested in accordance with the
requirements of this specification and Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The governing code for the mechanical design of plant piping systems is ASME B31.3 "Process Piping".
This code, together with the following codes, standards and references herein shall be deemed to be part of
this specification. All recommendations shall apply, unless specifically modified herein.

Unless specified otherwise in the Purchase Order/Contract, the current editions of the codes and standards
at the time of the Purchase Order/Contract shall be used.

American Society for Testing Materials (ASTM)

ASTM Standards Part 1 Steel Piping, Tubes and Fittings

American Society of Mechanical Engineers (ASME)

ASME I Boiler and Pressure Vessel Code, Power Boilers

ASME VIII Pressure Vessels - Division 1

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory-Made Wrought Steel Butt Weld Fittings

ASME B31.1 Power Piping

 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 9 of 39
Rev 0 1999

ASME B31.3 Process Piping

ASME B73.1M Horizontal End Suction Centrifugal Pumps for Chemical Process

National Electrical Manufactures Association (NEMA)

NEMA Code SM23 Steam Turbines for Mechanical Drive Services

American Petroleum Institute (API)

API 520 Sizing, Selection and Installation of Pressure Relieving Devices in Refineries

API 521 Guide for Pressure Relieving and Depressuring Systems

API 590 Steel Line Blanks

API 610 Centrifugal Pumps for General Refinery Service

API 611 General Purpose Steam Turbines for Petroleum, Chemical and Gas Industry Services

API 618 Reciprocating Compressors for General Refinery Service

API 2510 Design and Commissioning of LPG Installation

3.2 Plant Piping Arrangement

To achieve a safe operational and functional piping arrangement, equipment plot plans and piping studies
shall be developed in accordance with GES A.01.

Piping shall be routed to ensure that the shortest length and a minimum number of flanges, fittings and
valves are used. Allowance shall be made for future expansion, i.e headers fitted with blind flanges etc.

3.3 Design Pressure and Temperature

The design pressure and temperature of a piping system shall generally be in accordance with the technical
definitions, paragraph 2.1, with additional evaluations as given below:-

3.3.1 Surge Pressure

Surge is caused by rapid velocity changes of the fluid, through rapid valve closure, pump start-up and shut-
down, etc; and should be evaluated when it cannot be avoided by using appropriate means, i.e. using a non-
slam check valve.

3.3.2 Pressure/Temperature Variation

ASME B31.3 (Paragraph 302.2.4) provides allowances for pressure and temperature variation. The
Vendor/Contractor may only determine a maximum design pressure below the maximum surge pressure in
accordance with this allowance subject to approval by the Owner and only if major cost reductions can be
achieved.

3.3.3 Pressure Relieving Devices

The failure of pressure relieving devices shall not be taken into account when establishing the design
pressure of a system.

3.3.4 Vacuum Conditions

 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 10 of 39
Rev 0 1999

Piping subject to sub-atmospheric pressure shall be designed for full vacuum.

3.4 Line Sizing

3.4.1 General

The Vendor/Contractor shall be responsible for determine the size of all plant piping systems.

Line sizing for fire water lines may be covered under a fire water systems contract and shall be in
accordance with GES H.04.

3.4.2 Limitations

The nominal header size shall not be less than NPS 4

The nominal branch size shall not be less than NPS 2. Intermediate pipe sizes, other than those given in
GES P.01 shall not be used.

3.4.3 Procedures

The total pipe length and the equivalent lengths for valves and fittings shall be calculated and the allowable
pressure drop values determined.

Flow velocities to be used as a guide in tentative line sizing are determined by the following simple
formula: (Equation 1.)
4Q
v= Where v = velocity (feet/second)
π d2 Q = volume flow rate (cu.feet/second)
d = nominal diameter of pipe (feet)
 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 11 of 39
Rev 0 1999
The nomograph in Figure No.1 is based on the Fanning formula (Equation 2).

_p = 0.518fv²/d = 0.0864 fQ²/d5

_p = unit pressure drop psig/100 feet

f = friction coefficient
v = velocity in feet per second (from Equation 1)
Q = flow quantity (USGPM)
d = inside pipe diameter
f = (0.006 for new steel pipe)

The nomograph provides a quick means of calculating approximate pressure drop given the velocity, flow
quantity in US gallons per minute and an assumed line size.

Example: New steel pipe carrying 600 USGPM of water at 70 degrees fahrenheit, at a velocity of 7
feet per second will give a point "X" on the reference line. Connect point "X" with
"water" on density line to read 1.43 psig/100 feet.

The Vendor/Contractor shall submit detailed calculations for final line sizing and pressure drops, to the
Owner for approval.

3.5 Location of Piping

3.5.1 All piping entering and leaving a plot process area and within the process area shall be grouped together
where possible.

3.5.2 Piping inside the plot area shall be routed on overhead pipe racks where possible.

3.5.3 Off-plot piping shall be routed on concrete sleepers in grade pipe racks or on overhead pipe bridges if
space at grade level is limited.

Grade pipe racks shall cross roads by means of concrete culverts. Where this is impractical, due to local
grade road levels, overhead pipe bridges may be used.

3.5.4 The elevation of overhead piping shall be in accordance with GES A.01.

3.5.5 Pipe rack layout and design shall be in accordance with GES A.01.

3.5.6 Pipe trenches in process areas shall be avoided where possible, due to the hazard of inflammable gas
pockets collecting in open trenches.

3.5.7 Dead ends and low pockets in piping shall be avoided where possible, where they cannot be avoided, drain
valves shall be fitted.

4.0 PIPING EXPANSION AND FLEXIBILITY

4.1 General

Piping flexibility requirements shall be in accordance with ANSI B31.3 and the paragraphs below.

Piping flexibility analysis shall be based on the maximum and minimum design temperatures of the piping
system, according to the line list. The temperatures in the line list shall include all deviations e.g. steam
out, regeneration temperatures.

The use of cold spring shall be minimised but may be used to reduce deviation from installed dimensions
where necessary during initial operation to minimising the displacement of pipe hangers, etc. Credit for
 GENERAL ENGINEERING SPECIFICATION GES P.02
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cold spring is not allowed in calculating the magnitude of stress in stress range calculations.

The use of cold spring for piping connected to rotating equipment is not permitted.

4.2 Stress Calculations

Stress analysis shall be carried out using two methods.

a) By formal computer programme analysis.

b) By visual or approximate review.

The requirement of formal stress analysis of a piping system is dependant on the size of the piping and the
design temperature and may be determined by referring to Figure No 2, "Formal Stress Analysis
Requirements" of this specification. This is a minimum guideline and the Vendor/Contractor may adopt a
more conservative guide.

Piping connected to rotating equipment requires special consideration and shall generally be subject to
formal stress analysis. This requirement shall override the guideline set out in Figure No 2. Exceptions to
this rule may be applied to small bore auxiliary piping connected to the equipment. For example, lube and
seal oil piping.

The Stress Analysis Programme shall be submitted by the Vendor/Contractor for approval by the Owner or
Owner's representative.

4.3 System Flexibility

The piping layout shall be designed with adequate bends and offsets and where necessary horizontal
expansion loops to provide sufficient flexibility in the system, to prevent failure of piping and components
due to overstress, excessive moments and forces on equipment nozzles and leakage at flanged joints.

4.4 Expansion Joints

Expansion joints may be subject to leakage or failure and their use shall be minimised within process plant
battery limits, except where process requirements and space limitations dictate, i.e at catalytic cracking
reactor outlet piping. Expansion joints and victaulic couplings may be used at equipment such as water
storage tanks and large cooling water pumps.

The use of expansion joints or flexible couplings shall be avoided at fire water pumps and fire water
storage tanks.

4.5 Spring Hangers and Supports

4.5.1 General

Spring hangers and supports are used for allowing or absorbing vertical movement, while supporting a pipe
system. Their use should be minimized for reasons of cost, maintenance and set-up. The manufacturer's
name plate shall indicate the hot and cold set-up points.

4.5.2 Variable Spring Hangers and supports shall be provided with a scale giving the working load range and a
means of adjustment.

4.5.3 Constant Support Spring Hangers shall be provided with a scale showing the range of movement, an
accurate method of adjustment and with the calibration load clearly indicated.

4.6 Allowable Loads at Equipment

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4.6.1 Forces and moments imposed on mechanical equipment and vessel nozzles from piping systems shall not
exceed the manufacturer's recommended values. Standards for maximum allowable loads and moments
that may be imposed on nozzles at rotating equipment (if manufacturer's recommended values are not
provided) are given below:

4.6.2 Pumps

Allowable loads on centrifugal pump nozzles shall be in accordance with API 610 and/or ASME B73.1M.

4.6.3 Compressors/Turbines

Allowable loads on reciprocating Compressor Nozzles shall be in accordance with API 618.

Allowable loads on Steam Turbines for rotating equipment drive services shall be in accordance with Nema
Code SM 23 and API 611.

4.7 Anchors and Restraints

All piping shall be anchored at a process battery limit to prevent transmission of forces.

Piping restraints and anchors intended to limit moments and forces on rotating equipment shall be designed
to minimise deflection under load.

Anchors and restraints shall be provided on long runs of piping in a pipe rack to direct and distribute
thermal movements at offset legs, expansion loops etc;.

Anchors and restraints and associated expansion loops located in pipe racks shall be grouped together
where possible, so that the particular structural section of the piperack may be suitably braced to take the
imposed loads.

Anchors, supports and restraints for piping connected to compressors shall not be attached to the
compressor house structure.

Piping restraints and anchors for piping connected to reciprocating compressors and pumps, shall be
normally governed by a piping analogue study. These restraints and others for lines subject to slugging
shall be approved by the Owner.

5.0 PIPE SUPPORTS

5.1 General

The pipe supports for steel and alloy steel piping shall be designed for the weight of piping, filled with
water, during hydrotesting. Exceptions are where pneumatic testing of a system has been approved by the
Owner or where the weight of the process fluid plus insulation exceeds the weight of water filled bare pipe.

5.2 Support Spacing

5.2.1 Pipe supports shall be spaced so that there is no excessive deflection in the piping. Calculation of
allowable deflection in the pipe shall take into account the drainage of the line and the allowable stress in
the pipe, whichever gives the least deflection.

5.2.2 The operating temperature of the system shall be taken into consideration for support spacing. Lines that
are above 600°F (315°C) shall be calculated for maximum spans based on allowable stress.

5.2.3 The maximum support spacing for pipe racks shall be 20 ft (6.0m).
 GENERAL ENGINEERING SPECIFICATION GES P.02
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The maximum support spacing for individual steel pipe lines is given in the table below:

Maximum Spans for Straight Run Piping

NPS ½ ¾ 1 1½ 2 3 4 6

Span Feet 10 10 10 16 20 20 25 26
Span Metres 3.0 3.0 3.0 5.0 6.0 6.0 7.5 8.0

NPS 8 10 12 14 16 18 20 24

Span Feet 28 30 30 35 37 40 40 40
Span Metres 8.5 9.0 9.0 10.7 11.3 12.00 12.0 12.0

Notes: (a) Calculation is based on 3/8" (9mm) deflection

(b) Pipe is full of water, insulated for 600oF (315oC)
(c) Wall thickness of pipe is according to GES P.01.
(d) Calculation is for carbon and alloy steel pipe. Stainless steel piping with a
schedule of 10S wall thickness or less shall be calculated separately.

5.2.4 The support spacing of plastic pipe shall be to the manufacturer's standard.

5.3 Supporting of Small Bore Piping

The minimum line size for lines running along a piperack shall be NPS 2. Lines NPS 1½ and
below shall be increased to NPS 2 while on the pipe rack.

Individual small bore lines running outside the pipe rack area may be supported from an
adjacent larger line (NPS 6 and above), unless that line is electrically traced or cold
insulated.

5.4 Tower or Column Pipe Supports

Vertical lines at Towers or Columns shall be supported near the highest point of the line, as
close to the Tower nozzle as possible and then guided down the side of the Tower to a
horizontal leg.

5.5 Guide Spacing

5.5.1 General

Piping systems shall be guided so that thermal and dynamic movement is directed in the
required direction, thus limiting excessive lateral movement.

5.5.2 Spacing

Guide spacing shall be in accordance with Figure No.3 "Guide Spacing", of this Specification
and ANSI B31.3.

5.6 Standard Pipe Supports

The Vendor/Contractor shall supply a set of standard pipe support drawings to cover most
support situations for a particular Purchase Order/Contract. Standard pipe supports used
at the outset of the design phase, may be added to during the progress of the Purchase
Order/Contract.
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Standard supports shall be designed so that field adjustments may easily be made to pre-
fabricated support assemblies. The components listed below form part of the standard
support requirements.

5.7 Components for Standard Pipe Supports

5.7.1 If the fabrication of supports is sub-contracted, the Vendor/Contractor shall be

responsible for the quality and accuracy of the support fabrication.

5.7.2 Welded support trunnions shall be the same schedule and material as the pipe and
shall form part of the shop pipe fabrication. Trunnions shall have an allowance for field
cut adjustment.

5.2.3 Welded support attachments to piping shall be of similar material to the pipe. No
welding of attachments in the field shall be allowed on stress relieved piping.

5.2.4 Combination pipe support assemblies, using standard supports, are to be used in
preference to special pipe supports.

5.7.5 Dead-end extensions to piping shall not be used for supports. Trunnions or structural
steel sections shall be used for support extensions.

5.7.6 Hot insulated lines shall be supported on steel shoes, welded to the pipe. The
minimum height of the shoe shall be 4" (100mm). The height of shoes shall be increased
for insulation more than 3" (75mm) thick.

Clamped pipe shoes shall be used for stress relieved piping.

Non-insulated lines shall rest directly on steelwork, except where piping is subjected to
excessive or continuous movement, when shoes or wear pads shall be used.

5.8 Special Pipe Supports

Special pipe supports shall be designed by the Vendor/Contractor where none of the standard
supports or a combination thereof will suit a particular support problem. Standard
support components shall be used where possible in the design.

6.0 PIPE SPACING

6.1 General

Spacing between pipe centrelines shall be in accordance with Figure Nos 4 and 5.

Notes:

1. Dimensions given are for bare pipe to bare pipe. Spacing is based on 3" (75mm)
clearance between pipes.

2. If piping is insulated, insulation thickness to be added to the spacing above.

3. Allowance shall be made for orifice flanges, flanged valves and other flanged joints
in the piping.
 GENERAL ENGINEERING SPECIFICATION GES P.02
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7.0 SMALL BORE PIPING

7.1 Location of Branches

Small bore branch connections to headers can be prone to failure. The following points shall
be incorporated in the mechanical design.

a) branch connections shall be made in accordance with GES P.01, Branch Connection
Tables,

b) branches shall not be located in removable spools,

c) branches shall be located well away from sources of vibration.

If small bore branches on vibrating lines are unavoidable, branches shall be braced
back to the run pipe,

d) branches shall not be located in high stress areas,

e) consideration should be given to bracing of heavy or bulky components in small bore

piping.

7.2 Routing

Small bore lines should be grouped together where possible. Isolated small bore lines should
be run alongside larger piping or steelwork, even if the resulting routing is not the most
direct.

Support and guide spacing given in Section 5 and Figure No.3 shall be regarded as a
minimum requirement.

8.0 STEAM PIPING

8.1 General

Unit main steam distribution headers shall have a block valve and spectacle blind at the unit
battery limit, to allow for isolation of steam systems during maintenance of a process
unit.

Branch steam lines shall be connected at the top of the main steam header and shall have a
block valve at the high point of the branch line.

8.2 Condensate Collection

Saturated steam lines shall be provided with drip legs at low points. A steam trap shall collect
the condensate from the drip leg and discharge to the top of a condensate header, except
in isolated locations, where the steam trap may discharge to a sewer.

Drip legs shall be provided along saturated steam header runs at approximately 100 feet
(30m) intervals in the direction of steam flow. Drip legs shall also be provided in steam
mains at the upstream side of expansion loops.

Where a drip leg is installed at the bottom of a vertical steam riser, the pot size may be the
same size as the header, using a butt welded tee for steam lines up to NPS 12. Above
 GENERAL ENGINEERING SPECIFICATION GES P.02
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NPS 12, the line size shall be reduced to the pot size specified by the Vendor/Contractor.

Superheated steam mains or superheated steam distribution headers shall not be provided with
steam traps, except at the inlet to steam turbines.

8.3 Steam Traps

8.3.1 The size and type of steam trap shall be determined by the steam service and the
amount of condensate to be collected. The Vendor/Contractor shall provide a steam trap
schedule listing the size and type of all steam traps to be used in a plant, together with the
steam temperature and pressure, differential pressure and anticipated condensate
discharge. This schedule is subject to approval by the Owner.

8.3.2 Steam trap assemblies shall have a block valve upstream of the trap, a check valve
and block valve downstream of the trap, with a by-pass discharging to the condensate
return line. A bleed connection shall be provided before the inlet valve and a valved test
connection immediately after the trap. If an integral strainer is not provided with the trap,
a separate strainer shall be installed upstream of the trap.

8.3.3 The size of trap selected shall have a continuous discharge capacity of twice the
estimated condensate working load. The minimum size of steam traps shall be NPS ½ for
steam tracing and jacketing and NPS ¾ for all other steam services.

8.3.4 Traps shall preferably be the thermodynamic type for steam tracing and jacketing
and other small quantities of condensate and float and thermostatic type for medium
capacity condensate collection from large steam mains, steam coils etc. Inverted bucket
type lift traps should be used for large quantities of condensate.

Variations to these requirements shall be approved by the Owner.

8.3.5 Traps shall be located at grade or a permanent platform and be located as close as
possible to the condensate source.

9.0 PIPE, FITTINGS AND FLANGES

9.1 General

Materials for pipe and fittings shall be in accordance with GES P.01.

9.2 Changes of Direction

Changes of direction shall be made with long radius weld elbows in piping NPS 2 and above.
Short radius weld elbows shall be avoided. Mitred elbows may only be used on low
pressure lines NPS 30 and above when approved by the Owner.

9.3 Line Reduction

Butt weld reducers shall be used in piping NPS 2 and above. Swage nipples shall be used for
line reductions in small bore piping, including reduction from NPS 2 piping, unless
otherwise noted in the individual piping material specifications. Eccentric reducers shall
be used in horizontal lines and concentric reducers in vertical lines.

Screwed reducers shall be used for galvanized pipe NPS 3 and below.
 GENERAL ENGINEERING SPECIFICATION GES P.02
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9.4 End Closures

Dead ends of utility headers shall be flanged and blinded when future expansion is to be
allowed for. Weld caps shall be used when no future expansion is anticipated. End
closure plates shall not be used. Dead ends in process piping shall be avoided. Provision
for any future expansion shall be made in the run pipe.

9.5 Threaded Connections

Threaded connections shall be limited to galvanized steel pipe NPS 3 and below and
instrument connections after the first block valve in all other piping materials.

9.6 Elevation from Grade

The minimum distance between the bottom of run pipe to grade level shall be 12 inches
(300mm), unless governed by control valve elevations, header drains etc.

9.7 Installation of Flanges

The number of flanges in a piping system shall be kept to a minimum and should only be
installed to facilitate the fitting of flanged valves or components and where maintenance
and inspection locations are required or when process conditions dictate.
Flanged joints above roads shall be avoided. Flanged joints below air-fin coolers shall be
avoided. Flange selection shall be in accordance with GES P.01. Any substitution by the
Vendor/Contractor requires the Owner's approval.

10.0 PRESSURE BLINDS AND SPACERS

10.1 General

The term `pressure blinds and spacers', covers spectacle blinds, line blinds and spacers.
Pressure blinds and spacers shall be in accordance with API 590 `Steel Line Blanks' and
the Vendor/Contractor's standard drawings. Materials of fabrication shall be the same as
the relevant flange material as listed in the GES P.01 `Piping Material Specifications'.

10.2 Installation

All equipment shall be isolated by valve and blind without interfering with the operation of
the process units. Isolating valves and blinds for tall vertical vessels shall be located near
grade or near a pipe rack. Pressure blinds and spacers shall be installed in all lines
containing hydrocarbons and steam at the unit-battery limit, at inlets and outlets to fired
heaters and all compressor suction and discharge lines. In addition to the above, pressure
blinds and spacers shall be installed where indicated on the piping and instrumentation
diagrams.

10.3 Spectacle Blinds

Spectacle blinds shall be used in preference to blinds and spacers, but shall be limited by
handling and weight restrictions.

Space should be provided around the blind to allow for swinging of the spectacle blind on its
swing bolt. Pressure blinds and spacers 65 lbs (30kg) in weight and below shall be the
spectacle blind type, line blinds and spacers shall be used when this weight is exceeded.

10.4 Jack Screws

 GENERAL ENGINEERING SPECIFICATION GES P.02
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Jack screws shall be installed at every pressure blind and spacer location.

Jack screws shall be square head, case hardened steel set screws,threaded to full length.

11.0 VALVES

11.1 General

11.1.1 The quantity and type of valves in piping systems shall be kept to a minimum. Valve
selection shall be in accordance with GES P.01.

11.1.2 Any substitution proposed by the contractor requires the Owner's approval.

11.1.3 Valves located above roads shall be avoided.

11.1.4 All lines entering or leaving a process area battery limit, shall have a block valve and
spectacle blind. A drain or vent connection shall be located close to the battery limit
valve. Battery limit valves shall be grouped together and operated from a battery limit
walkway.

11.2 Valve Access Requirements

11.2.1 All valves should be easily accessible for operation and maintenance and be reached
from grade or a platform, except as noted in paragraph 11.2.4 below.

11.2.2 The maximum operating hand wheel height above the operating level shall be 4.5 ft
(1.4m) for frequently operated valves and 6.75 ft (2.1m) for infrequently operated valves.
Valves above the operating heights given above, from grade level may be operated by a
chain wheel, see paragraph 11.3 below. This does not apply to valves below NPS 2
which are infrequently operated.

11.2.3 Valve handwheels shall not obstruct walkways or platforms. Valve handwheels shall
preferably be positioned with the stem pointed upwards. Valve stems in a horizontal
position shall not project into an operating access area, particularly at head height.

Valves shall not be installed with stems below the horizontal position.

11.2.4 Valves below NPS 2 that are infrequently operated and are elevated above 6.75 ft
(2.1m) above an operational level may be reached by a permanent ladder.

11.3 Chain Operators

Frequently operated valves above 6ft (1.8m) operating height to the handwheel, may be
operated by a chain and chainwheel from grade. Chainwheels shall be kept to a minimum
and are only to be used where lack of space precludes the installation of a platform.
Chainwheels should preferably not be used from an elevated platform or walkway.

11.4 Gear Operators

Gear Operators shall be provided to ease the operation of larger and/or high pressure valves.
Size and pressure requirements for gear operators are shown on the material data sheets
in GES P.01. Exceptions to these requirements may only be applied to large low pressure
valves that are frequently operated, subject to approval by the Owner.

11.5 Full Port Valves

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Full Port Ball Valves shall be used where process conditions, such as critical pressure drop do
not permit regular port (reduced internal diameter) valves, or where special requirements
cannot permit a reduced bore, e.g. scraper lines, relief valve inlet lines and hot taps.

11.6 Valves In Steam Service

All branch lines from steam headers shall be provided with a block valve, which shall be
located as close as possible to the header, preferably at the highest point of the branch
line.

Block valves in steam service should not be located in downward flow vertical lines
supplying steam turbines, or upstream of control valve stations.

Block valves in steam service for ANSI Class 600 Rating and above and NPS 2 and larger
shall have Butt-Weld End bodies with pressure seal bonnets.

Block valves in vertical steam piping shall be provided with a drip ring above the valve and a
drain running from the drip ring to a steam trap.

Block valves in steam service shall be provided with a warm-up by-pass in accordance with
note 1, valve summary notes, GES P.01.

11.7 Valves In Hydrogen Service

Valves in services for fluids containing hydrogen, ANSI Class 600 Rating and above, shall be
the butt-welding end type with pressure seal bonnets.

11.8 Bleed Valves

A NPS 3/4 bleed valve, plugged, shall be provided at the following locations:

a) Between all double valves.

b) Between a pressure safety valve and inlet and outlet valves where specified.

c) Between equipment isolation valves and equipment nozzles. A bleed valve may
combine the role of a drain or vent valve in this case.

11.9 Valve Stem Extensions

Extension stems shall be installed on valves with hand wheels located at or below a platform
level. For valves NPS 4 and below, field fabricated extension stems may be used, for
valves NPS 4 and above, manufactured extension stems are to be installed.

12.0 HEAT EXCHANGER PIPING

12.1 General

Piping shall be designed so that full access is available for tube bundle pulling and cleaning.
Sufficient removable spools shall be provided in the piping between the block valve and
exchanger nozzle for channel head removal.

Piping shall not be supported from the exchanger shell.

Piping shall not cross over the channel head or shell. Elbow nozzles on exchangers shall be
 GENERAL ENGINEERING SPECIFICATION GES P.02
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avoided, except where a saving in elevation is necessary.

Piping to and from an exchanger or group of exchangers shall be grouped together where
possible.

12.2 Design

12.2.1 A uniform height for a bank of exchangers at grade, or elevated in a structure, shall
be determined by lining-up the bottom of the shells. The minimum height is usually
determined by the bottom outlet piping at the largest exchanger.

12.2.2 Clearances

The minimum recommended clearances between exchanger shells and between pipeways and
exchanges should be in accordance with GES A.01.

12.3 Reboilers

Where a thermosyphon reboiler return nozzle is not direct coupled to a tower nozzle, the
reboiler return piping shall be designed for the shortest possible route between tower and
reboiler, with the minimum numbers of bends, in order to minimise pressure drop. The
design should also consider flexibility and nozzle loading limitations. The liquid draw-
off line to the reboiler does not have the same critical pressure drop requirements. Where
two reboilers are specified, in a thermosyphon circuit, the piping for draw off and return
circuits shall be symmetrical.

12.4 Vents and Drains

Shell and channel piping shall be provided with vent and drain connections between the
nozzle and the block valve. These connections may be utilised for chemical cleaning, if
specified.

13.0 PUMPS, COMPRESSORS AND TURBINES

13.1 General

Piping at pumps, compressors and steam turbines shall be sufficiently flexible and properly
supported to ensure that equipment nozzles are not subjected to stress that could lead to
misalignment or casing distortion.

Piping shall be arranged to allow removal of casing and machinery internals with minimum
disturbance to piping. Auxiliary piping should be routed neatly along the baseplate and
shall not obstruct inspection covers, casing or any other item requiring access for
maintenance and operation, or extend across an operating floor.

Lube and seal oil lines shall not be routed in the vicinity of hot process and utility lines.

13.2 Pump Piping

13.2.1 Pump suction piping shall be routed with consideration of the net positive suction
head requirements and thus shall be arranged for the shortest and most direct route from
the suction vessel, consistent with flexibility and access requirements. Pump suction
lines shall not have pockets.

13.2.2 Suction and discharge nozzles should never be larger than line size. If this occurs,
 GENERAL ENGINEERING SPECIFICATION GES P.02
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the suction and discharge line sizes and the pump data requirements should be re-
calculated.

Where a horizontal suction nozzle is smaller than line size, an eccentric reducer shall be
installed at the suction nozzle with the flat part of the reducer located topside, to prevent
pump cavitation.

For vertical suction and discharge nozzles smaller than line size, concentric reducers shall be
installed.

13.2.3 Suction lines shall have a 3-diameter straight run upstream of the pump nozzle. This
length shall not include reducers or fittings.

13.2.4 A strainer shall be installed in each pump suction line. Strainers may be temporary
or permanent depending on the process requirements. Strainers shall be of a type that do
not require dismantling pump piping. Temporary conical or "Witches-Hat" type strainers
shall not be used.

13.2.5 A block valve shall be installed in the suction line of each pump, upstream of the
strainer.

13.2.6 A block valve and check valve shall be installed in each pump discharge line. The
check valve to be located upstream of the block valve.

13.2.7 When there is a standby pump in a pair of pumps, the piping shall be symmetrical
where possible. In addition, a NPS 3/4 warm-up by-pass with a globe valve shall be
installed upstream of the discharge check valve and downstream of the discharge block
valve, if the operating temperature of the pump is above 450oF (230oC).

13.2.8 Positive displacement pumps shall be safeguarded from pressure surge at start-up, or
from a possible blocked outlet, by a relief device installed in the discharge line between
the pump and the block valve.

13.3 Compressor Piping

13.3.1 General

In order to prevent fatigue failure of compressor piping, the effects of vibration and pressure
surge shall be considered.

Piping shall have a minimum of overhang. Double offsets for directional change shall be
avoided where possible.

Line routing between the suction drum and compressor nozzle can be critical, the design
should provide a route as short as possible to provide a direct gas flow, taking into
consideration line flexibility. Any increase in configuration is liable to cause an increase
in line size.

The design of piping in the compressor area should provide as much operating space as
possible on the operating floor. Where compressors are elevated, process and utility
piping should be located underneath the operating floor where practicable.

Interstage and discharge piping shall be sufficiently flexible to allow for thermal expansion
due to compression.

13.3.2 Block valves shall be installed in suction and discharge lines, except for air
compressors, when block valves shall only be in the discharge piping.
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Discharge lines shall have a check valve located between the outlet nozzle and the block
valve. The type of check valve to be used is specified in GES P.01.

13.3.3 A strainer shall be installed in each compressor suction line downstream of the block
valve located as close as possible to the suction nozzle.

13.3.4 Suction piping between a knockout drum and the compressor suction nozzle shall
slope back toward the knockout drum, without pockets, except where suction and
discharge nozzles located beneath the compressor casing dictate the piping layout.

13.3.5 The pressure rating of a suction line block valve and piping between this valve and
the suction nozzle should be the same rating as the discharge line for that particular
compressor stage, including any valves and suction pulsation dampeners.

13.3.6 Piping configuration analysis for all piping, pulsation devices and equipment
between the first major vessel upstream and downstream of the compressor, shall be in
accordance with Section 3.9, API 618. Results and recommendations of the analysis
shall be submitted to and approved by the Owner. Piping design shall not change after
the analysis recommendations have been implemented, unless sanctioned by the Owner.

13.3.7 Reciprocating compressor suction and discharge lines shall be located close to grade
to permit installation of restraints.

13.3.8 Reciprocating compressor intake and interstage piping system shall be pickled and
passivated, rinsed, dried and sprayed with oil internally.

13.4 Steam Turbine Piping

13.4.1 General

The steam supply line connection shall be located at the top of the steam header. A block
valve shall be installed in the steam supply line and located close to the steam header. A
steam separator and steam trap shall be provided in the steam inlet line. The piping
design shall ensure that all pockets in the steam supply line are trapped and no slugs of
condensate can enter the turbine. A Y-type strainer shall be installed in the steam supply
line upstream of the system control valve.

Warm-up facilities for the turbine shall be provided. Piping shall be designed to allow steam-
blowdown, up to the inlet and outlet flanges of the turbine before start-up.

13.4.2 Large Condensing Turbines

The main steam inlet throttling valve is located at the turbine steam inlet nozzle and is
normally supplied by the turbine manufacturer. A control valve and stop valve shall be
installed in the main steam supply line. These items shall be installed at the operating
floor level.

Steam vacuum ejector valves and piping for the surface condenser should also be located at
the operating floor level.

13.4.3 Back-Pressure Turbines

The main steam line shall have a vertical condensate drip leg and steam trap, before the
control valve at the steam inlet.

The exhaust steam may either discharge to an exhaust head or low pressure steam main.
 GENERAL ENGINEERING SPECIFICATION GES P.02
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An exhaust head is used where the steam turbine is in a remote location, or it is not economic
otherwise to discharge to a low pressure steam header. When the turbine exhausts into a
low pressure steam header, the steam exhaust line shall tie-in to the top of the header. A
block valve shall be installed in the exhaust line at the high point.

A condensate leg shall be installed in the exhaust steam line close to the turbine exhaust
nozzle. A relief valve shall be installed on the exhaust steam side of the turbine. This
valve shall discharge to atmosphere at a safe location.

It should be noted that exhaust steam will be superheated when leaving the turbine, if the
exhaust steam line ties into a low pressure header, care must be taken to ensure that the
low pressure line is desuperheated if the header is to be used for supplying utility hose
stations.

14.0 TOWERS AND DRUMS

14.1 Piping Design

14.1.4 Piping running vertically down the side of a tower shall be grouped together close to
the side facing the pipe rack and shall be adequately supported and guided from the tower
shell.

14.1.2 Valves and spectacle blinds where required at vessel nozzles shall be installed
immediately adjacent to the vessel.

14.1.3 Piping and valves shall not impede access at platforms, ladders and to manways.

14.1.4 If steam piping to a tower or drum for steam-out purposes does not have a flanged
pressure blind, there shall be a removable spool between the steam block valve and check
valve installed on the vessel side. This spool shall only be installed during the steam-out
operation and removed when normal operation is resumed, or during inspection.

14.1.5 All valves on vertical vessels shall be located outside the skirt. There shall be no
flanged or threaded connections inside the skirt.

14.1.6 All elevated valves NPS 2 and above shall be operable from a vessel platform.
Valves NPS 1½ and below may be operable from a ladder.

14.1.7 Instrument piping shall be designed so that all instruments shall be accessible from a
vessel platform, excepting multiple level gauges which may be read from a ladder.

15.0 FIRED HEATERS AND BOILERS

15.1 General

Piping design shall provide adequate access and clearance for removal of headers and tubes.
Burner piping shall be designed with sufficient clearance to remove burners. Flexible
hose shall not be used in burner piping, unless the burner gun position requires
adjustments. The location of access doors, explosion hatches, peepholes etc; shall be
subject to approval by the Owner.

15.2 Operating Access

 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 25 of 39
Rev 0 1999

Burner hand control valves shall be located adjacent to observation doors or peepholes, to
permit burner adjustment while observing the burner flame.

Pilot valves shall be installed in a position that enables the operator to open the pilot valve
with one hand and ignite the pilot with the other. For pilots installed in the heater floor,
the pilot valves shall be located so that the operator can position himself between the
burner and the nearest exterior heater wall.

15.3 Fuel Oil Piping

A main fuel oil supply and return line shall be installed for each furnace. Dead-end headers
shall be avoided. Block valves shall be installed in the main fuel oil inlet and outlet lines
of the furnace. These valves shall be located a minimum of 75 ft (23m) from the outside
face of the furnace. The fuel oil return line shall be supplied with a throttling valve,
downstream of the last burner take-off. This valve shall be accessible from a platform.

Lines carrying fuel oil heavier than 30o API shall be heat traced. Fuel oil supply lines to
individual burners shall be insulated together with the atomizing steam leads.

Fuel oil valves to individual burners should be located as close as possible to the header, to
minimize dead legs.

The main fuel oil supply line shall be equipped with a fine mesh duplex strainer.

15.4 Fuel Gas Piping

A main fuel gas supply line shall be installed for each furnace. A knockout drum shall be
installed in fuel gas and pilot gas systems to collect condensate. The drain line from the
knock-out drum shall discharge to a closed system. A block valve shall be installed in the
gas supply line to the furnace. This valve shall be located a minimum of 50 ft (15m)
from the knockout drum and 75 ft (23m) from the outside face of the furnace.

A drain leg shall be supplied at the low point of the fuel gas system downstream of the control
valve and discharge into the drain line from the knockout drum. Supply leads to
individual burners shall be connected at the top of the supply header.

A plug valve shall be installed in each burner lead for manual adjustment of the fuel gas
supply.

A duplex fine mesh strainer shall be installed in the pilot gas line upstream of the pressure
reducing valve.

15.5 Atomising Air

Air is not recommended for atomisation, if specifically required then advice of the Burner
Vendor should be sought.

15.6 Atomising Steam

If steam is used for atomisation a dedicated steam branch line shall run to each furnace from
the steam header. This branch line shall connect to the top of the steam header.

A block valve shall be installed in the steam branch line, close to the steam header and at the
top of the branch line.

Individual atomizing steam leads shall be connected to the top of the steam branch line. Each
 GENERAL ENGINEERING SPECIFICATION GES P.02
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Rev 0 1999
lead shall have a check valve and block valve operable from grade or a platform, located
adjacent to the peephole.

The steam branch line shall be provided with a drip-leg and trap at each low point.

15.7 Snuffing and Purge Steam

Purge steam shall be provided to purge the combustion chamber. Snuffing steam shall be
provided to the return header housing of furnaces using rolled headers or headers with
screw or plug type closures.

Snuffing and purge steam systems shall comprise of steam supply lines from the main steam
header to a valve manifold located at grade and a minimum of 50ft (15m) from the
furnace limits, in a location easily accessible from an access road.

The manifold shall consist of separate take-offs each with a block valve and run to the
snuffing steam and purge steam connections at the furnace.

The steam supply lines shall be provided with a drip-leg and steam trap at the low point of the
manifold. 1/8" (3mm) drain holes are to be provided directly above the snuffing steam
valves at the manifold. These holes are to be located away from the manifold operating
position.

15.8 Boiler Piping

External boiler piping integrated within the boiler system and not supplied by the Boiler
Vendor, shall generally be in accordance with GES F.02, GES F.04 and GES F.09.

In addition to the above specifications, the following requirements also apply.

Boiler drains and sample connections shall be piped to grade.

Pressure relief valves discharging to atmosphere shall be piped to a safe location.

Drains from superheater headers shall have separate connections to the sewer to permit
observations of flow.

15.9 Sootblower Steam Piping

Sootblower steam piping shall generally be in accordance with GES F.10 and the following
requirements.

Sootblower steam systems shall be designed to prevent condensate from entering the soot
blower during the blowing cycle. The piping system shall be sloped and trapped to
provide continuous drainage to sewer.

16.0 STORAGE TANKS

16.1 Atmospheric Storage

Piping shall be sufficiently flexible to compensate for tank settlement and thermal expansion.
Flexible joints shall not be used for tank piping containing hydrocarbons or other
hazardous fluids.

Where there are two or more nozzles located at the base of the tank, adjacent nozzles shall be
located parallel to the horizontal centreline of the tank.
 GENERAL ENGINEERING SPECIFICATION GES P.02
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Block valves shall be located directly against the nozzles where possible.

Tank lines shall have a minimum of one elbow between the tank nozzle and the bundwall.

Piping running to and from the storage tank shall be grouped together and run at grade on
concrete sleepers 12 inches (300mm) minimum above the grade level, except as noted in
Section 9.6.

Lines shall penetrate bund walls using pipe sleeves. Sleeves shall be fitted with proprietary
end seals. Lines passing through sleeves shall be centralised by plastic insulators at 5 feet
(1.5m) centres. Lines shall be tape wrapped (55% overlap) to extend 4 ft (1.2m) beyond
sleeve ends.

Tank piping shall not pass through the bund wall into another bunded area or designated fire
block area. Transfer pumps and valve manifolds shall be located outside the bunded area.

16.2 Pressurised Storage (excluding refrigerated storage)

All bottom piping at spheres shall be fully welded. All inlet and outlet lines shall have a shut
off valve, located at the shell nozzle. In addition, a remote operated emergency shut off
valve shall be provided in each line, at a manifold separation wall 15 ft (5m) away from
the sphere (unless the first shut-off valve is remote operated from a safe location). All
valves shall be the fire-safe type. All piping shall have the same flexibility requirements
as laid down in paragraph 16.1 above.

17.0 VENTS AND DRAINS

Valved vent and drain connections shall be installed at all high and low points of piping
systems for hydrostatic testing and shall be NPS ¾ except for NPS ½ lines. Valved vent
and drain connections shall also be provided where required for process and operations.

Drain points releasing hazardous or toxic fluids shall discharge safely to an appropriate closed
drain system.

All other vent and drain points shall be plugged or capped.

18.0 SAMPLE CONNECTIONS

18.1 General

The following paragraphs cover the requirements for obtaining manual samples of liquid or
gaseous fluids from piping and process equipment.

Sample points shall be double valved. A block valve shall be installed close to the header or
equipment and a hand control valve shall be located at the sampling point.

18.2 Location

18.2.1 Sample points shall be located at convenient operating points.

18.2.2 Sample points shall preferably be located at grade, or if not practicable, at a

permanent platform.

18.2.3 Sample points should not be located in dead-ended access ways and should be
 GENERAL ENGINEERING SPECIFICATION GES P.02
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located to allow the operator to take a sample upwind of the sample point.

18.2.4 Sample points shall not be taken from the bottom of a horizontal line. Liquid sample
points should be located on the horizontal axis of a line. Gas samples shall be taken
from the top of the line.

18.3 Gas Samples

Samples of gaseous fluids or liquids that could vaporize shall be obtained by using a
commercially available sample bottle assembly.

18.4 Liquid Samples

Consideration should be given to sampling of non-vaporizing liquids that could be injurious

to the operator, in this case, a protective enclosure of a design subject to the Owner's
approval shall be provided.

18.5 Sample Cooler

A sample of hot fluid shall be cooled by means of a sample cooler. The sample cooler may
either be the Vendor/Contractor's own design, or a commercially available product and
shall be subject to the Owner's approval.

The sample cooler shall reduce the temperature of the sample to 140oF (60oC) or less, but not
below a temperature of 25°F (14oC) above the pour point of the liquid, or to a
temperature which would result in a viscosity greater than 500 centipoise.

The cooling medium shall be taken from the nearest available service water or cooling water
system.

19.0 INSTRUMENT CONNECTIONS

19.1 General

The following paragraphs cover the installation of instruments in process and utility piping
and hook-up requirements at vessels, for normal refining and petrochemical facilities.
Cryogenic service conditions are not covered in this specification.

All process instrument connections, (except temperature connections) shall be valved.

19.2. Location

Locally mounted instruments shall be accessible from grade or permanent platforms.

All instruments shall be installed in piping and at vessels so that there is sufficient space
around the instrument for installation and maintenance. In particular, there should be
sufficient clearance between orifice metering assemblies and adjacent piping.

Where instruments are mounted on vessels, they should be located so that they do not project
into access ways at platforms.

19.3 Temperature Connections

19.3.1 Thermowells shall be provided for all temperature measuring elements.

Thermowells shall be NPS 1 threaded NPT, for standard thermowell installations for
 GENERAL ENGINEERING SPECIFICATION GES P.02
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Rev 0 1999
pressure ratings, ANSI Class 150 and 300.

19.3.2 NPS 1½ flanged thermowells shall be provided for pressure ratings of ANSI Class
600 and above and where frequent inspection is required. The minimum line size for
straight take-off connections shall be NPS 4 and NPS 3 for thermowell insertions at
elbows. For the latter case, the thermowell shall be located opposite the direction of
flow. Piping below the minimum sizes above shall be swaged up locally.

19.3.3 Thermowells installed in vessels shall be NPS 1½ flanged with a minimum rating of
ANSI Class 300.

19.4 Pressure Connections

Locally mounted pressure indicators should be located so that they are easily read from grade
or a permanent platform.

All pressure connections shall be accessible for maintenance.

All pressure connections shall be valved ½" at the piping termination point.

19.5 Flow Instruments

19.5.1 General

The installation of orifice flanges and other flow instruments shall be in accordance with GES
J.02, Section 6 and the following requirements.

19.5.2. Location

Orifice flanges in elevated horizontal lines shall be located for easy maintenance access from
temporary scaffolding or mobile platforms.

Lines running in a pipe rack that have orifice flanges installed, shall be located at the edge of
the pipe rack. Other flow instruments e.g. turbine meters, variable area meters, shall be
accessible from grade or a permanent platform. Where these instruments are located in a
horizontal run, the distance from the piping centreline to grade or platform shall be a
minimum of 18 inches (450 mm).

Where orifices flanges are installed in vertical piping, the following requirements apply:

Service Installation

Liquid Lines - The flow must be up

Steam Lines - The flow must be down
Gas Lines - The flow must be down

Orifice taps shall be located at 45 degrees from the horizontal axis.

Flange tap locations shall be as follows:

Gas Lines - Taps located upward

Steam & liquid - Taps located downward

19.6 Level Instruments

The installation of level instruments shall be in accordance with GES J.03 paragraph 3.5 and
Section 6 and the following requirements.
 GENERAL ENGINEERING SPECIFICATION GES P.02
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Rev 0 1999

19.6.1 Standpipes

Where multiple level gauges are specified, a common standpipe shall be used. A level
displacer, where specified, may also be mounted from the same standpipe if space is
restricted at a vessel. Loads on vessel nozzles should be considered when a standpipe is
used. The minimum pipe size for standpipes shall be NPS 2.

19.6.2 Permanent access from grade or a platform is required for level displacers and level
alarm instruments.

19.7 Control Valves

The installation of control valves shall be in accordance with GES J.06, Section 6.0 and the
following requirements.

19.7.1 Location

All control valves shall be located at grade or a permanent platform.

The control valve centreline shall be a minimum of 24 inches (600mm) above the operating
level, for NPS 10 and below. Control valve manifold sizes NPS 12 and above shall be
individually calculated. A minimum clearance of 12" (300mm) shall be maintained
above the valve actuator. A flanged elbow spool shall be installed either upstream or
downstream of the control valve for ease of valve removal.

19.7.2 Steam Service

For control valves in steam service a vertical drip leg, with a steam trap shall be installed
upstream of the control valve. The first block valve of a control valve manifold shall be
located downstream of the drip leg and mounted horizontally adjacent to the control
valve. A plugged NPS ¾ drain valve shall be installed immediately upstream and
downstream of the control valve for pressure letdown and drainage.

20.0 RELIEF AND BLOWDOWN SYSTEMS

20.1 Design

All relief headers entering or leaving a flare seal or blowdown drum, shall slope towards the
drum with a minimum fall of 1" in 40 ft (1 in 500).

20.1.2 The minimum height of the relief system piping shall be above the height of the inlet
piping into the top of the flare blowdown drum. Relief headers shall be routed either in
the pipe rack or above the piperack, supported on tee-post supports forming an extension
of the pipe rack columns.

20.1.3 Branch lines shall preferably tie-in to the top of the flare headers. Large sub-headers
may tie-in at the horizontal centreline of the relief header whenever there are height
restrictions.

20.1.4 Branch lines NPS 3 and above shall tie-in to the relief header at an angle of 45
degrees, in the direction of flow. Lines NPS 2 and below shall tie-in at 90o degrees to the
header.

20.1.5 Relief headers shall be provided with purge points at the end of the headers at the
high points of the system. Headers shall be purged and pressurized with fuel gas. The
 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 31 of 39
Rev 0 1999
fuel gas lines shall be provided with a globe valve and check valve located close to the
flare header and a block valve near the fuel gas header.

20.1.6 Relief systems shall not be pocketed. If an expansion loop is required in a relief
header, the fall in the line shall include the loop length.

20.2 Pressure Safety Relief Valves

20.2.1 General

The installation of pressure safety relief valves and rupture discs shall be in accordance with
GES J.10 Section 6 and the following requirements.

20.2.2 Location

A minimum clear space of 2.5 ft (0.75m) shall be maintained for access at each side and at the
front of a safety relief valve.

Sufficient vertical clearance shall be provided between the safety relief valve cap and any
obstruction above, so that the cover may be removed for maintenance. This vertical
clearance is normally specified by the valve manufacturer.

20.2.3 Block Valves

An inlet block valve shall be installed when the vessel or associated plant cannot be shut
down for safety relief valve maintenance. A block valve shall be installed on the outlet,
when the safety relief valve is discharging into a closed system serving other safety relief
valves. Inlet and outlet block valves shall be full port, line size and locked open.

Where a standby safety relief valve is installed, the block valves of both sets shall be
interlocked so that one set is locked open and the other set locked closed.

A NPS ¾ bleed valve shall be installed between the inlet block valve and the safety relief
valve and also between the outlet block valve and the safety relief valve.

20.2.4 Maintenance

Safety relief valves NPS 3"x 2" and below, with inlet pressure ratings of ANSI Class 150 or
300, may be handled manually. Safety relief valves above this size and rating will
require mechanical facilities for handling. A locally mounted davit or runway beam may
be used for lifting safety relief valves or alternatively a mobile crane may be used for
safety relief valve maintenance. Handling facilities for safety relief valves shall be
approved by the Owner.

20.2.5 Inlet Piping

The inlet pipe size shall not be less than the relief valve inlet. Inlet piping shall rise toward
the safety relief valve and have no pockets.

20.2.6 Outlet Piping

Where a safety relief valve is discharging to atmosphere, a weep hole ¼" (6mm) diameter
shall be drilled at the low point of the pipe. When the discharge is to a relief system, the
 GENERAL ENGINEERING SPECIFICATION GES P.02
PLANT PIPING SYSTEMS Page 32 of 39
Rev 0 1999
discharge line shall slope from the relief valve discharge and connect to the top of the
flare line, with no pockets.

21.0 COOLING SYSTEMS

21.1 Air-Fin Coolers

Piping shall be designed to give a balanced flow to all nozzles. Piping shall be designed and
supported to minimize loads on air fin cooler nozzles.

Adequate platforming shall be provided for access to cooler motors and mechanical
equipment.

21.2 Cooling Water Supply and Return

Main cooling water headers shall be provided with drains at the lowest points to enable
complete system draining within 6 hours.

Branch lines NPS 2 and below shall not be taken from the bottom of headers to prevent
plugging of lines. Cooling water supply to exchangers shall always enter at the bottom
nozzle from an above supply line and leave at the top nozzle, for cooling efficiency and
in the case of failure of the cooling water supply, the exchanger will remain full of water.

22.0 UTILITY STATIONS

22.1 General

The location of utility stations shall be shown on the plot plan. Each hose station shall have a
maximum radius of 50 feet (15m).

The utility station system shall cover all the equipment shown on the plot plan, with the hose
station radii overlapping for maximum coverage.

22.2 Design

Utility stations shall supply water, air and steam utilities and shall have NPS 1 hose
connections. Each station shall supply utilities in the same sequence facing the operator,
i.e. W.A.S (Water, Air and Steam). Nitrogen hose points shall be installed in areas where
nitrogen purge connections are specified. The nitrogen hose point shall be adjacent to the
steam hose connection.

Each service shall have a dedicated hose coupling, to prevent any error in connection. Hose
couplings shall be located 4 ft (1.2m) above grade, in a horizontal position. The steam
hose downcomer shall have a drip leg with a NPS ½ trap.

Utility stations located at tower platforms, shall be positioned outside the handrailing, with the
hose connections 12 inches (300mm) above the handrail, located horizontally and facing
inwards.

The extent of utilities to be supplied to elevated equipment including Towers and Columns
shall be specified by the Owner.
GENERAL ENGINEERING SPECIFICATION GES P.02
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Rev 0 1999
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES P.07

UNDERGROUND PIPING

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 2 of 15
Rev 0 1999

INDEX

SECTION TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Installation 7
3.3 Layout 8
3.4 Trench Excavation and Backfill 9
3.5 Terminations above Ground 9
3.6 Cathodic Protection 10
3.7 Stress and Supports 10
3.8 Pipe Joints Below Ground 10

4.0 MATERIALS 10

4.1 General 10
4.2 Process Plant Cooling Water Systems 11
4.3 Fire Mains 11
4.4 Potable Water 11
4.5 Summary of Materials 11

5.0 FABRICATION 12

5.1 Piping Fabrication Procedure 12

6.0 INSPECTION 12

6.1 Procedures 12
6.2 Scope 12

7.0 TESTING 12

7.1 Required Tests 12

7.2 Test Procedures 13
7.3 Test Certificates 13

INDEX
 GENERAL ENGINEERING SPECIFICATION GES P.07
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Rev 0 1999
SECTION TITLE PAGE

8.0 DOCUMENTATION 13

8.1 Introduction 13
8.2 Schedules and Reports 13
8.3 Data and Calculations 13
8.4 Drawings 13
8.5 Fabrication 14

9.0 PRIOR TO SHIPMENT 15

9.1 Protection 15
9.2 Warranty 15
 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 4 of 15
Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the design, fabrication, installation, inspection
and testing of underground piping for refineries, onshore oil and gas installations and processing
facilities, including piping items purchased either directly or as a part of a package.

1.1.2 This specification is limited to below ground process piping, process drains, including fire water
mains, foam lines (where specified) cooling water lines, mains water supply and plant potable water
supply. All piping shall be in accordance with the above ground piping specification GES P.01
"Piping Material Specification" and GES P.02 "Plant Piping Systems" and any additional requirements
of this specification.

1.1.3 This specification only covers underground pressure piping within the pressure/temperature range of
Class 150, ASME B16.5, within the temperature limits of -20°F(-29°C) to 200°F(93°C).

1.1.4 This specification does not cover the general requirements for rainwater, oily water and sanitary sewer
systems, see GES Q.07 for these requirements.

1.1.5 Pipeline systems are outside the scope of this specification and are provided for under GES R.02
"Pipeline Systems".

1.1.6 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exceptions must be authorised in writing by the Owner.

1.1.7 In the event of any conflict between this specification and any of the applicable codes and standards,
the Vendor/Contractor shall inform the Owner in writing and receive written clarification before
proceeding with the work.

1.1.8 This General Engineering Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

The following NOC specifications are an integral part of this specification and any exceptions shall be
approved in advance by the Owner:

GES H.04 Firewater Systems

GES P.01 Piping Material Specification

GES P.02 Plant Piping Systems

GES P.06 Plastic and Glass Fibre Piping

GES P.08 Cement Lined Piping

GES P.09 Steel Piping Fabrication (Shop or Field)

GES P.10 Erection and Testing of Steel Piping

GES P.11 Fabrication and Installation of Plastic Lined Piping

GES Q.01 Earthworks (Inc Site Preparation, Pits and Trenches)

GES Q.04 Concrete Structures

 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 5 of 15
Rev 0 1999
GES Q.07 Rainwater, Oily Water and Sanitary Sewer Systems

GES X.04 Epoxy Lining of Steel Piping and Vessels

GES X.07 Coating and Wrapping of Buried Pipework

GES X.22 Cathodic Protection Systems for Plant and Pipelines and Well Casings

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Design Drawings (Studies)

Conceptual drawings for a plant EPIC (Engineering, Procurement, Installation and Commissioning)
contract may be supplied by the Owner to the Vendor/Contractor or by the Vendor/Contractor to the
Owner, which together with the technical specification defines the scope of work of the Purchase
Order/Contract.

Detail Engineering Drawings

Working drawings proposed by the Vendor/Contractor prior to commencement of construction.

Pipe Liner

A filled or unfilled thermoplastic or thermosetting resin layer, reinforced or non-reinforced forming

the interior surface of the pipe.

Surge Pressure (Water Hammer)

A short term pressure increase greater than working pressure that is anticipated in a system as a result
of a change in velocity of a fluid, e.g. when valves are opened/closed or when pumps are
started/stopped.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Contractor

The main contractor for a defined piece of work

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority
 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 6 of 15
Rev 0 1999
The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of
this specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verifies that the equipment and facilities have been designed, constructed, inspected
and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The governing codes for buried piping are ASME B31.3 "Process Piping" for steel piping and
thermoplastic piping and AWWA C950 "Fibre Glass Pressure Pipe" for GRP piping. These codes
together with the specifications listed in Section 1.2 and the following codes and standards shall be
deemed to be part of this specification. All recommendations shall apply, unless specifically modified
herein.

National Fire Protection Association (NFPA)

NFPA 11 Standard for Low Expansion Foam

 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 7 of 15
Rev 0 1999
3.2 Installation

3.2.1 Depth of Cover (To Top of Pipe)

Depth of Cover in Feet (Metres)

Accessible to Traffic Inaccessible to Traffic
Steel Piping
(Coated & Wrapped) 2'(0.6m) 1'(0.3m)
Fire Water Lines

Steel Piping
(Plastic Lined) 2'(0.6m) 1'(0.3m)
Fire Water Lines

Steel Piping
(Coated & Wrapped) 2'(0.6m) 1' (0.3m)
NPS 24 and Below

Steel Piping
(Plastic Lined) 2'(0.6m) 1' (0.3m)
NPS 24 and Below

Steel Piping
(Coated & Wrapped) 3'(0.9m) 2' (0.6m)
Above NPS 24

Steel Piping
(Plastic Lined) 3'(0.9m) 2' (0.6m)
Above NPS 24

Glass-Reinforced
Plastic Pipe 4'(1.2m) 3'(0.9m)
(GRP)

Steel Piping
(Cement Lined) 4'(1.2m) 3'(0.9m)
 GENERAL ENGINEERING SPECIFICATION GES P.07
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Rev 0 1999
3.3 Layout

3.3.1 Cooling Water Lines in Process Areas

Buried cooling water piping in Process Areas shall be laid out with consideration to other underground
services in the same vicinity, e.g. sewers and cable trenches. In general, where there is an interference
in elevation between underground services, sewers, which are limited by gravity fall, and cable
trenches, which are normally near or at the grade level, shall take priority in elevation.

Underground lines shall be grouped together, in a common trench where feasible, with a common
bottom of pipe elevation.

Where two or more lines are running parallel, they shall have a minimum distance of 1.0 ft (0.3m)
between the outside diameters of the lines. This dimension may be reduced for short distances in
congested areas.

The minimum clear distance between buried lines, where lines cross, shall be 0.5 ft (0.15m).

The minimum clear distance between buried piping operating at ambient temperatures and electrical
and instrument cables shall be 1.0 ft (0.3m). The minimum clear distance between buried piping
operating above ambient temperatures to a maximum of 140°F (60°C) and electrical and instrument
cables shall be 2.0 ft (0.6m).

Valves in buried lines shall be accessible from installed valve boxes, so that the valve may be operated
either by extension key from grade, or from the floor of the valve box. The valve box shall be
provided with ladder access to the floor,and shall be designed to provide sufficient space at one side of
the valve for access and maintenance. Where a valve is remotely operated, adequate space shall be
provided for the actuator. The concrete valve box shall be designed in accordance with GES Q.04.
Instruments, e.g. flow meters, in buried lines shall be located in installed instrument boxes, which
shall be designed to provide sufficient space for maintenance of the instrument. Provision shall be
made so that the instrument maybe read locally from grade level, in addition to any remote reading
requirements.

3.3.2 Fire Water Mains

Fire water ring mains, particularly when constructed of GRP material, shall generally be buried when
located around process areas and tankage areas for protection from a hydrocarbon fire and located just
off the hard shoulder of access roads, for protection from accidental damage from vehicles.

Valves in buried fire mains shall be installed in accordance with GES H.04, paragraph 3.3.

3.3.3 Foam Lines

Foam lines within a dyked area containing storage tanks for flammable liquids or within 50 ft (15m) of
a tank that is not dyked, shall be buried with a minimum cover of 1 ft (0.3m), in accordance with
NFPA 11.
 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 9 of 15
Rev 0 1999
3.4 Trench Excavation and Backfill

Trenches for buried lines, lined or unlined, shall be excavated to the required widths as listed in Table
A below.

TABLE 1 - "Minimum Trench Widths"

Pipe Size (NPS) Minimum Trench Width Inches (m)

4" 18" (0.45m)

6" 20" (0.50m)

8" 22" (0.55m)
10" 24" (0.60m)
12" 26" (0.65m)
14" 28" (0.70m)

16" 30" (0.75m)

18" 32" (0.80m)

20" 36" (0.90m)

24" 40" (1.00m)

30" 46" (1.20m)

36" 52" (1.30m)

42" 58" (1.50m)

48" 64" (1.60m)

The above table covers individual lines. When two or more lines are routed together in a common
trench, then half the above values shall be taken for each outside line in a bank, plus the minimum
spacing between lines, shall be taken when calculating the minimum trench width.

Excavation and backfill for buried lines, lined or unlined, shall generally be in accordance with GES
Q.07, Section 5.2. The minimum soil cover for GRP buried piping shall be not less than 2.5 ft
(0.76m).

Backfilling shall not take place, until field hydrostatic testing is completed and the pipe has been
examined for leaks.

3.5 Terminations Above Ground

All underground pipe connections to above ground location shall terminate with a flange, 1 ft (0.3m)
above grade, to the face of flange.

There shall be no butt welded, socket welded or threaded terminal points above grade.

Where an underground line ties into a horizontal valve manifold above grade and there is insufficient
room for fittings and flanges elevation wise, the terminal flange shall be in the horizontal plane at the
 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 10 of 15
Rev 0 1999
manifold elevation. The underground piping contract shall include all above ground piping and
fittings as far as the terminal flange.

Terminal points to above ground equipment such as heat exchangers shall be located so that an
adjustable pipe spool may be installed between the terminal flange and the equipment nozzle.

3.6 Cathodic Protection

Underground steel piping shall be cathodically protected against corrosion in accordance with GES
X.22.

3.7 Stress and Supports

It is not anticipated that there shall be any requirement for evaluation of stresses resulting from
temperature within the scope of this specification. Buried piping is subject to restraint against
movement from soil resistance. The design of underground piping shall nevertheless allow for
horizontal legs in branch lines to compensate for horizontal movement of a header, or vertical
movement of risers connecting to above ground piping. Risers projecting through concrete paving
effectively form an anchor.

Underground lines shall be laid and embedded on an annulus of clean sand in the trench, so that all of
the underground piping is continuously supported. The remainder of the backfill shall be installed so
that the sand pad is not disturbed.

Where GRP bell and spigot pipe is installed, concrete thrust blocks shall be installed in accordance
with the requirements of GES P.06.

3.8 Pipe Joints Below Ground

There shall be no buried flange connections in any buried pipework. Steel pipes, other than
galvanised, will have fully welded joints, galvanised pipework will have threaded joints. GRP
pipework shall have permanently fused joints.

4.0 MATERIALS

4.1 General

Material for underground pressure piping for water systems is dependant upon the quality of the water
supply, the service required and the degree of soil corrosiveness in the plant area.

The minimum size for underground water distribution headers shall be NPS 4.

The minimum size of underground branch lines shall be NPS 2.

Transition joints from underground to above ground piping shall be flanged, underground piping shall
have the same flange rating and facing as the above ground piping. Insulating flange sets shall be
installed at the transition joints.

4.2 Process Plant Cooling Water Systems

Underground cooling water lines in process plant areas normally carry treated raw water or
desalinated water, unlined carbon steel welded pipe, externally coated and wrapped, shall be used.
 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 11 of 15
Rev 0 1999
Note

If process plants on the coastline use seawater for cooling, then cement lined steel piping shall be used
for this service.

Most soils are likely to be moderate to severely corrosive, carbon steel underground piping in low to
moderately corrosive soils shall be coated and wrapped in accordance with GES X.07. GRP materials
may be selected for highly corrosive soils.

4.3 Firemains

Underground firewater ring mains may use either seawater or raw water from wells. Cement lined or
plastic lined carbon steel pipe, externally coated and wrapped, shall be used for sea water or raw water
with a high salinity content. Epoxy lined carbon steel pipe shall be used for raw water with a low
salinity content.

GRP material may be used as alternative to the above, in areas with highly corrosive soil, for sea water
or raw water with either a high or a low salinity.

4.4 Potable Water

Material for underground potable water lines shall be galvanized carbon steel. Minimum branch size
shall be NPS 2.

4.5 Summary of Materials

Carbon steel underground piping materials shall be in accordance with GES P.01.

Epoxy lining of steel pipe shall be in accordance with GES X.04.

Cement lined or plastic lined piping shall be in accordance with GES P.08 and GES P.11 respectively.

Glass fibre reinforced plastic (GRP) and thermoplastic piping material shall be in accordance with
GES P.06.

The cost effectiveness of using GRP material as opposed to plastic or cement lined steel pipe,
externally coated and wrapped, where there is both an internal and external corrosion problem shall be
assessed by the Vendor/Contractor, selection of material shall be subject to approval by the Owner.
The Vendor/Contractor should consider the relative weakness of GRP piping material in comparison
to steel pipe and the severity of soil corrosion, when making an assessment.

For static water conditions such as fire water mains when the raw water supply is mildly corrosive,
corrosion inhibitors shall be considered and assessed instead of using lined pipe, subject to approval
by the Owner.

5.0 FABRICATION

5.1 Piping Fabrication Procedure

5.1.1 The fabrication of unlined carbon steel underground piping shall be in accordance with GES P.09.

5.1.2 The fabrication of internally epoxy coated or cement lined pipe shall be in accordance with GES P.08.
 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 12 of 15
Rev 0 1999
5.1.3 The fabrication of plastic lined carbon steel piping shall be in accordance with GES P.11.

5.1.4 The fabrication of glass reinforced plastic and thermoplastic underground piping shall be in
accordance with GES P.06.

5.1.5 All carbon steel buried piping shall be coated and wrapped in accordance with GES X.07.

6.0 INSPECTION

6.1 Procedures

The Vendor/Contractor shall allow the Inspector free access to all areas of fabrication, installation and
testing.

The Vendor/Contractor always has the responsibility to provide adequate quality control and
inspection of materials. Any inspection by the Owner or his Inspector shall not relieve the
Vendor/Contractor of these responsibilities or those under his guarantees.

6.2 Scope

The inspection of carbon steel underground lines, unlined, internally coated, cement lined or plastic
lined are governed by ASME B31.3, and shall be in accordance with the requirements of GES P.09,
GES X.04, GES P.08 and GES P.11 respectively.

The inspection of GRP piping is governed by AWWA C950, and ASME B31.3 Chapter VII and shall
be in accordance with the requirements of GES P.06.

The inspection of thermoplastic piping is governed by ASME B31.3 Chapter VII, and shall be in
accordance with the requirements of GES P.06.

7.0 TESTING

7.1 Required Tests

All underground steel piping, unlined or lined shall be pressure tested in accordance with the
requirements in ASME B31.3.

All underground piping of thermoplastic material shall be tested in accordance with the requirements
of ASME B.31.3 Chapter VII, and the relevant standards in ASTM Section 8.

All underground piping of GRP material shall be tested in accordance with AWWA C950.

Pressure and leak tests shall be carried out in the presence of the Owner's Inspector.

7.2 Test Procedures

7.2.1 Test procedure for unlined steel buried lines shall be in accordance with GES P.10 Section 8.

7.2.2 Test procedures for lined steel buried lines shall be in accordance with GES P.11 Section 8.

7.2.3 Test procedures for internally coated and cement lined piping shall be in accordance with GES X.04
Section 8 and GES P.08 Section 12 respectively.

7.2.4 Test procedures for GRP piping and thermoplastic piping shall be in accordance with GES P.06
Section 8.
 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 13 of 15
Rev 0 1999

7.3 Test Certificates

Test certificates for the successful testing of the underground pressure piping shall be submitted by the
Vendor/Contractor in accordance with the appropriate specifications as listed above in the test
procedures.

8.0 DOCUMENTATION

8.1 Introduction

8.1.1 This section covers the documentation required for the design, fabrication, installation and testing of
underground piping.

8.2 Schedules and Reports

The Vendor/Contractor shall supply a schedule showing the documents for review and approval,
proposed sub-contractors, material procurement and a production/fabrication programme.

8.3 Data and Calculations

8.3.1 Project specific instructions will be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted, and the methods of submission.

8.3.2 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.

8.3.3 All calculations shall be carried out in clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Codes, the source of these formulae or methods shall
be clearly referenced.

8.3.4 Computer calculations will only be acceptable if all input is shown, together with calculated values of
intermediate terms, factors and options chosen, including final calculated dimensions, stresses or other
values and the computer program has been validated to the satisfaction of the Owner.

8.4 Drawings

Process and Instrumentation diagrams (P&IDs) and piping general arrangements shall be submitted to
the Owner and/or Inspection Authority for review and approval. "Issued for Construction" status
drawings shall be issued after final approval.

8.5 Fabrication

8.5.1 Documentation of all welding, fabrication and construction activities shall be maintained. It is the
responsibility of the Vendor/Contractor to collate all documentation and certification relating to a
specific contract and to generate and issue Data Books in accordance with Contract requirements.

These data books as a minimum requirement shall include the following, where applicable:

(a) Quality plans,

(b) Manufacturer's material certificates of conformity and Test Reports,

(c) Description and location of all repairs,

 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 14 of 15
Rev 0 1999

(d) Tie-in temperatures and location of all tie-ins,

(e) All survey data and as-built drawings,

(f) Grade and wall thickness of the pipe and fittings,

(g) Welding procedures,

(h) Welding qualification procedures,

(i) Welding/Material maps,

(j) Notes on land reinstatement, including any drainage modification,

(k) Details of cathodic protection system,

(l) Details of other buried installations crossing the underground piping,

(m) Pressure test procedures,

(n) Pressure test reports,

(o) Inspection reports,

(p) Concession documents,

(q) Release notes.

8.5.2 Following completion of construction work, all appropriate documentation and certification necessary
to complete the contract data shall be collated, checked and authorised by the Inspector prior to
despatch to the Owner. Two (2) copies of the completed Data Books shall be despatched to the
Owner.

The manuals shall be presented in A4 format, securely bound in heavy duty 4 ring binders.

8.5.3 The Vendor/Contractor shall supply one set of reproducible original drawings.

9.0 PRIOR TO SHIPMENT

9.1 Protection of Underground Piping against Damage in Storage, Transport and Handling.

Plastic and GRP Piping and fittings shall not be shipped, stored or handled at temperatures below the
recommended minimum limit established in ASME B31.3, Appendix F, for the specific grade under
consideration.

All pipes, fittings and specials shall be protected against damage in storage, transport and handling,
e.g. by using straw or wood wool pads.

Care must be taken during loading, handling and lifting of any section of pipe. Slings shall be used
for lifting pipes, the use of hooks in pipe ends is not permitted. Pipe and fittings shall be adequately
braced, supported and protected from vibration during transit and tied down to prevent shifting or
distortion of pipe sections.
 GENERAL ENGINEERING SPECIFICATION GES P.07
UNDERGROUND PIPING Page 15 of 15
Rev 0 1999

9.2 Warranty

The Vendor/Contractor shall warrant all equipment, materials and services supplied against any defect
for a period of 12 months after commissioning or 24 months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs
associated with restoring the equipment to the standard specified by the Purchase Order/Contract.
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES X.01

SURFACE PREPARATION AND PAINTING APPLICATION

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 2 of 21
Rev 0 1999

INDEX
SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Exclusions 4
1.3 Exceptions 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 CODES AND STANDARDS 5

4.0 QUALITY ASSURANCE AND INSPECTION REQUIREMENTS 7

4.1 Quality System 7

4.2 Quality Control Plan 7
4.3 Inspection 7

5.0 SURFACE PREPARATION STEEL 7

5.1 General 7
5.2 Preliminary Inspection 7
5.3 Preliminary De-contamination 7
5.4 Testing for Presence of Corrosion Salts 8
5.5 Edges, Corners and Welds 8
5.6 Abrasive Blasting 8
5.7 Quality Control of Cleaned Surfaces 9

6.0 PREPARATION OF OTHER SUBSTRATES 10

6.1 Galvanised Surfaces 10

6.2 Stainless Steel and Aluminum Surfaces 10
6.3 Passive Fire Protection Surfaces 11
6.4 Wood Surfaces 11

7.0 PREPARATION OF PREVIOUSLY COATED SURFACES 11

7.1 Preparation of Coated Surfaces for Overcoating 11

7.2 Sweep Blasting 12
7.3 Priming Delay of Prepared Surfaces 12
7.4 Fabrication Welds 12
7.5 Surfaces Primed with Holding Primer 12

8.0 PROCUREMENT AND STORAGE PAINT MATERIALS 12

8.1 Approval 12
8.2 Uniformity of Sourcing 12
8.3 Delivery and Shelf Life 13
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 3 of 21
Rev 0 1999

SEC TITLE PAGE

8.4 Condition of Paints 13

8.5 Storage Conditions 13
8.6 Manufacturer's Requirements 13
8.7 Standard Labelling 13
8.8 Sampling of Paints/Coatings 13

9.0 PREPARATION OF PAINTING/COATING MATERIALS 14

10.0 PAINT/COATING APPLICATION 14

10.1 General 14
10.2 Brush Application 14
10.3 Spray Application 14
10.4 Ambient Conditions 15
10.5 Overpainting/Coating 15
10.6 Overspray 15
10.7 Requirements for Zinc - Rich Primers 15
10.8 Handling 16

11.0 REPAIR OF DEFECTS 16

11.1 Defects Revealed by Blast Cleaning 16

11.2 Damage Substrate 16
11.3 Repair of Galvanising 16

12.0 TESTING AND INSPECTION 16

12.1 General 16
12.2 Test Equipment 17
12.3 Test Methods to be Adopted During Painting/Coating Operations 17

13.0 HEALTH AND SAFETY 19

13.1 General 19
13.2 Abrasive Blasting 19
13.3 Painting and Coating Operations 19
13.4 Skin Irritants 19

14.0 REPORTING 19

14.1 Status and Progress Report 19

14.2 Completion Records 20

15.0 CLEAN-UP 20

16.0 STORAGE OF PAINTED ITEMS 20

Table 1 Dew Point Determination 21

 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 4 of 21
Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for surface preparation, painting coating
application, inspection, quality control, testing and painting system guidelines for the application of
protective or maintenance coatings to equipment and structures.

1.1.2 The details specified are minimum requirements only and the Vendor/Contractor shall select an
appropriate system and provide full details for approval.

1.1.3 In the event of any conflict between this specification and any of the applicable Codes and
Standards, the Vendor/Contractor shall inform the Owner in writing and received written
clarification before proceeding with the work.

1.1.4 This General Engineering Specification shall form part of all Purchase Order/Contracts.

1.2 Exclusions

1.2.1 The following metallic surfaces and materials shall not be painted or coated, unless otherwise
specified, e.g. for fluid identification purposes:

- Aluminium and aluminium alloys exposed to a controlled environment.

- Uninsulated duplex and superaustenitic stainless steels, with an operating surface
temperature less than 120°C.
- Uninsulated 18/8 type stainless steels, with a surface operating temperature below 50°C.
- Copper and copper alloys.
- Nickel and nickel plated materials.
- Zinc coated surfaces (electroplated or galvanised) exposed to a controlled environment.
- Brass, lead and other metals resistant to atmospheric corrosion.
- Valve stems and threads, actuators, linkages.
- Machined and gasket surfaces.
- Manufacturer finished items (including nameplates).

The following non-metallic surfaces and materials do not require painting or coating unless
specifically required.

- Building bricks, masonry units and wall tiles.

- Concrete structures and foundations.
- Plastic and plastic coated materials.
- Concrete or gunite fireproofing.
- Glass and other materials resistant to atmospheric corrosion.

1.3 Exceptions

Where the Vendor/Contractor wishes to deviate from this specification in any way, all details of
materials, components, equipment, procedures for testing, and remedies shall be submitted for the
Owner's approval. Proposals for changes shall be made within 3 months of award of Purchase
Order/Contract, or within such time that should the proposals not be approved, the work when
executed in accordance with this specification, will not affect the overall schedule.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 5 of 21
Rev 0 1999
2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Holiday

A discontinuity in a protective coating that exhibits electrical conductivity when exposed to a

specified voltage test.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and
facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner, or Vendor/Contractor that verifies that the equipment
and facilities have been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verifies that the equipment and facilities have been designed, constructed, inspected
and tested in accordance with the requirements of this specification and the Purchase
Order/Contract.

3.0 CODES AND STANDARDS

The painting/coating application design shall comply with this specification and the following
Codes and Standards. Unless specified otherwise in the Purchase Order/Contract, the latest
editions of Codes and Standards at the time of the order shall apply.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 6 of 21
Rev 0 1999
The following Codes and Standards, together with the references therein, shall be deemed to form
part of this specification. All recommendations shall apply unless specifically modified herein.

3.1.1 British Standards

BS 2842 Whirling Hygrometers

BS 3900 Methods of Test for Paints
BS 5493 Code of Practice for Protective Coating of Iron and Steel Structure Against
Corrosion.
BS 7079 Preparation of Steel Substrates before Application of Paints and Related Products.

3.1.2 Swedish Standards

SIS 05 5900 Preparation of Steel Substrates before Application of Paints and Related
Products

3.1.3 American Standards

ASTM - American Society for Testing and Materials

ASTM D-1186 Measuring of Dry Film Thickness of Nonmagnetic Organic Coatings on a

Magnetic Base

ASTM D-1212 Measuring of Wet Film Thickness of Organic Coatings

ASTM D-1400 Measuring of Dry Film Thickness of Nonmetallic Coatings of Paint,

Varnish, Lacquer, and Related Products Applied on a Nonmagnetic Metal
Base.

ASTM D-4541 Pull Off Strength Test using Portable Adhesion Tester

SSPC - Steel Structures Painting Council

SSPC 1-10 Pictorial Surface Preparation Standards for Painting Steel Surfaces.

NACE - National Association of Corrosion Engineers

NACE RP 0188 Discontinuity (Holiday) Testing of Protective Coatings

NACE TM 0170 Visual Standards for Preparation of New Steel

3.1.4 German Standards

DIN 8201 Part 6: Synthetic Mineral Abrasives; Electric Corundum

DIN 8201 Part 9: Synthetic Mineral Solid Abrasives; Copper Refining Slag and
Melting Chamber Slag

3.1.5 International Standards

ISO 9000 Quality Management and Quality Assurance Standards - Guidelines for
Selection and Use

ISO 8501-1 Preparation of Steel Substrates before the Application of Paints and Related
Products.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 7 of 21
Rev 0 1999
ISO 8501-2 Preparation of Previously Painted Surfaces.

3.1.6 Specified or Approved Coating Manufacturer's Product Application Data Sheet

4.0 QUALITY ASSURANCE AND INSPECTION REQUIREMENTS

4.1 Quality System

The Vendor/Contractor shall operate a Quality System in line with ISO 9000.

4.2 Quality Control Plan

Before commencement of the work, Vendor/Contractor shall supply to the Owner, for approval, a
Quality Control Plan consisting of items listed below, including applicable standards, proposed
acceptance criteria, certifying documents and inspection points for the Purchase Order/Contract.

- Control of raw materials.

- Inspection system and procedures.
- Inspection equipment.
- Calibration of equipment.
- Blending and painting controls.
- Record keeping and procedures.

4.3 Inspection

The Vendor/Contractor shall furnish reasonable site facilities for the Owner's Inspector and shall
allow the Inspector access to all aspects of the work.

5.0 SURFACE PREPARATION OF STEEL

5.1 General

The preferred method of surface preparation is by dry abrasive blasting, all other methods of
surface preparation, e.g. wet abrasive blasting, power tool cleaning, acid etching etc., shall not be
used unless prior approval is given by the Owner.

5.2 Preliminary Inspection

Before the commencement of abrasive blasting all surfaces shall be inspected for defects, including
but not limited to, sharp edges (min radius 2mm), surface lamination, weld spatter, porous welds,
weld undercuts, weld scars, and any other surface irregularity likely to hinder correct surface
preparation. Any defects discovered shall be remedied and approved by the Inspector, before work
begins.

5.3 Preliminary De-contamination

5.3.1 Prior to surface preparation by abrasive blasting, all traces of hydrocarbon (oil, grease, etc.)
contamination, mineral contaminants, e.g. muck, welding residues, salts (including zinc salts), etc.,
shall be removed.

5.3.2 Greases and dirt shall be removed by emulsions of organic solvent in water, heated to between 10°C
to 70°C, sprayed onto the work, followed by thorough water rinsing and/or either steam cleaning or
controlled high pressure water jets. Typical solvents to be used are turpentine, white spirit and
trichloro-ethane.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 8 of 21
Rev 0 1999

5.3.3 Hydrocarbon deposits shall be solvent cleaned in accordance with SSPC SP1, followed by washing
and rinsing.

5.3.4 Mineral deposits shall be removed by the application of a bio-degradable industrial detergent
and/or scrubbing with stiff bristle brushes using a solution of 2% of the detergent in fresh water
followed by high pressure jetting. The cleaned surface shall be rinsed with clean fresh water and
allowed to dry. Rags shall not be used for drying.

5.4 Testing for Presence of Corrosive Salts

Steel items that have either been exposed to a salt laden atmosphere or stored in contact with the
ground, may become pitted and shall be tested for the presence of corrosion promoting salts. This
shall be carried out prior to abrasive blast cleaning, power or hand tool cleaning. Testing shall be
with potassium ferrocyanide test papers in accordance with Appendix G of BS 5493. Any salts
discovered shall be removed by washing in accordance with Section 5.3 and the surface retested.

5.5 Edges, Corners and Welds

5.5.1 Edges prepared for welding shall be abrasive blast cleaned and masked to a distance of 4" (100mm)
from the weld before priming. Subsequent coats applied before welding shall terminate 2.5"
(60mm) from the termination of the primer coat.

5.5.2 All sharp edges, corners and welds shall be rounded to a minimum radius of 1/16" (2mm) and/or
smoothed by grinding. Any major defects, particularly surface laminations or scabs, likely to be
detrimental to the protective coating systems, shall be removed by suitable dressing. Defects
revealed during blast cleaning and subject to dressing shall be reblasted.

5.5.3 All bolt holes shall be drilled and de-burred before blast cleaning.

5.6 Abrasive Blasting

5.6.1 General

Prior to abrasive blasting, all equipment that could be damaged by blast, dust or particulate matter
shall be suitably protected by wrapping, taping, or other means to prevent damage. Threaded holes
shall be plugged before blasting.

5.6.2 Techniques and Restrictions

(a) Grit blasting shall not be done in areas close to painting/coating operations and wet coated
surfaces to prevent dust and grit contamination. Grit blasting shall be permitted only
during the daylight hours, except that rough grit blasting will normally be allowed during
the night under artificial light, with the approval of the Inspector, providing that the surface
shall be given a final blasting to the specified standard in daylight.

(b) Final surface preparation shall not be carried out when:

- the relative humidity is more than 85%;

- the temperature of the surface is less than 3°C above the dew point of the
surrounding air or outside the limits set by the manufacturer;
- the wind is raising dust, during rain, or when any of these conditions are imminent.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 9 of 21
Rev 0 1999
5.6.3 Abrasives

(a) Approved abrasives for blast cleaning are as follows:

(i) Copper slag abrasive to DIN 8201 Part 9;

(ii) Aluminum Oxide abrasive, natural or synthetic to DIN 8201 Part 6.

(b) All abrasives for blast cleaning shall be clean, dry and of correct particle size to produce the
profile specified for the coating to be applied and shall not leave any residue embedded in
the profile of the blast cleaned surface.

(c) The size of abrasives used shall be in accordance with DIN 8201 and the following:

(i) 0.25 - 0.5 mm to provide a surface profile of 10-35µm;

(ii) 0.5 - 1.0 mm to provide a surface profile of 35-75µm;
(iii) 1.0 - 2.0 mm to provide a surface profile of 75-100µm.

(d) The abrasive mixture shall be replenished using new and worn abrasive so as to produce a
consistent profile height and standard of surface cleanliness. The abrasive mixture shall be
kept free of dust, including metallic particles, and debris.

(e) Expendable abrasive used for blast cleaning shall be free of contaminants, e.g. chlorides and
other soluble salts, shall not contain metallic copper and not more than 2% by weight of
copper oxide. The mixing of abrasives for carbon steel, stainless steel and other alloys is not
permitted.

(f) Expendable abrasive shall not be recycled. Sand shall not be used for blast cleaning.

5.6.4 Air Quality

Compressed air supplied for surface preparation shall be free of oil and condensed water as
determined by a daily blotter test. If necessary, after coolers shall be provided to reduce the water
content of the compressed air.

5.6.5 Blasting Equipment and Air Pressure

(a) Abrasive blasting equipment shall be of intrinsically safe construction and equipped with a
remote shut off valve triggered by the release of a dead man's handle at the blasting nozzle.

(b) Where air-operated equipment is used, the operators' hood or headgear shall be ventilated
by clean, cool air served through a regulator filter, to prevent blast cleaning residues from
being inhaled.

(c) The supply of compressed air for blast cleaning shall provide a pressure of 100psig
(700kPag) at each blast nozzle. Compressors and hoses shall be sized to enable this
pressure to be maintained with the nozzle size(s) selected and making allowance for nozzle
wear.

5.7 Quality Control of Cleaned Surfaces

5.7.1 The quality for blast cleaning and other surface preparation methods shall be defined by SSPC,
NACE, BS 7079, SIS 05 5900 and ISO 8501-1. The equivalence of these standards in descending
order of surface preparation is as follows:
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 10 of 21
Rev 0 1999
Surface Preparation Standard SSPC/NACE SIS 05 5900/ BS 7079/ ISO 8501-1

White Metal Blast Cleaning SSPC-SP5/NACE#1 SA3

Near White Metal Blast Cleaning SSPC-SP10/NACE#2 SA2½
Commercial Blast Cleaning SSPC-SP6/NACE#3 SA2

5.7.2 The amplitude of the profile of the blast cleaned surface shall be stated in the relevant coating
schedule, though maximum amplitude of 100 microns shall not normally be exceeded.

5.7.3 SIS 05 5900, BS 7079 and ISO 8501-1 provide interchangeable pictorial interpretations of standards
of blast cleaning from four initial rust grades A, B, C and D. One of these pictorial standards shall
be used to confirm that the appropriate level of surface preparation has been achieved.

5.7.4 Any contamination of blast cleaned surfaces by oil or grease shall be removed by swabbing with
xylol or similar approved solvent and the surface reblasted to the required standard.

5.7.5 All dust, abrasives and/or other debris shall be removed from the surface by vacuum cleaning or
blowing with clean dry compressed air.

6.0 PREPARATION OF OTHER SUBSTRATES

6.1 Galvanised Surfaces

6.1.1 Galvanised surfaces shall be thoroughly degreased by solvent cleaning in accordance with SSPC
SP1 or by high pressure water jetting after applying an approved biodegradable industrial detergent
and rinsed before any other surface preparation takes place.

6.1.2 Zinc salts, if present, on the galvanised surface shall be removed by high pressure water jetting with
fresh water, scrubbing with fresh water and stiff bristle brushes or by sand papering, or by any
combination of all three needed to achieve complete removal of the salts.

6.1.3 Galvanised items welded permanently to supporting members before or after the latter are primed
shall, except for the weld and galvanised steel within 2" (50mm) of the weld, be effectively protected
from abrasive blast. Galvanised surfaces exposed to the blast shall be primed at the same time as
the supporting structure. Galvanised surfaces not required to be coated shall be effectively masked
to protect them from overspray.

6.2 Stainless Steel and Aluminum Surfaces

6.2.1 The surface shall be thoroughly degreased by solvent cleaning in accordance with SSPC SP1 or by
high pressure water jetting after applying an approved biodegradable non-caustic detergent and
rinsed.

6.2.2 The surface shall be scrubbed with fresh water and stiff bristle brushes or washed by high pressure
water jetting to remove soluble contaminants and allowed to dry.

6.2.3 Fresh water containing a maximum content of 50ppm of chloride, shall be used in hand or power
washing and rinsing.

6.2.4 The surface shall be lightly but thoroughly abraded to a uniformly matt appearance by sand
papering or abrasive blasting with non-metallic abrasive. Metal brushes and needles shall not be
used.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 11 of 21
Rev 0 1999
6.3 Passive Fire Protection Surfaces

6.3.1 Cementitious Surfaces

Surfaces of Pyrocrete, Mandolite and cement-bound finishing of fibrous protection, e.g. ceramic
fibre, shall be sand papered to remove nibs and sharp edges. Cavities and cracks shall be filled with
two-pack epoxy knifing compound.

6.3.2 Surfaces of Intumescent Fire-Protection

Surfaces of Chastek and similar epoxy based materials shall be lightly abraded to enable adhesion
by the finish coating system and to remove nibs and sharp edges. Any pronounced ripples shall be
filled with a two-pack epoxy knifing compound.

6.4 Wood Surfaces

6.4.1 Wood surfaces shall not be painted/coated when the moisture content of the timber measured with
an electric moisture meter exceeds 12%, for interior surfaces, and 18%, for exterior surfaces.

6.4.2 Hardwoods or softwoods for which a clear finish is specified shall be rubbed down with abrasive
paper to give a smooth surface which shall be free from contaminating substances, scratches and
other imperfections.

6.4.3 Surfaces which are to be painted/coated shall be rubbed down to remove all contaminating
substances and imperfections which would be visible in the finished paint film.

6.4.4 The surfaces of knots and resinous streaks shall be painted with two coats of knotting, the first
allowed to dry before the second is applied.

6.4.5 Where the surfaces are suspected of being infected with mould they shall be thoroughly treated
with a fungicide.

7.0 PREPARATION OF PREVIOUSLY COATED SURFACES

7.1 Preparation of Coated Surfaces for Overcoating

7.1.1 Painted/coated surfaces which have been exposed to a marine or industrial atmosphere shall be
cleaned of airborne contaminants (see Section 5.3) by washing with clean fresh water and shall be
allowed to dry before overcoating.

7.1.2 All deposits, whether organic or mineral, shall be removed as required by Section 5.3.

7.1.3 All defective coating on the surface shall be removed by scraping, abrasive paper or sweep blasting
in accordance with Section 7.2 until a sound surface is obtained.

7.1.4 All gloss surfaces shall be rendered matt by sanding with abrasive paper, or sweep blasting in
accordance with Section 7.2.

7.1.5 At areas of patch repairs, a 2" (50mm) margin of the existing painting/coating shall be prepared.
This margin shall be feathered to a fine edge by sanding, taking care not to damage the base coat on
the repair area.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 12 of 21
Rev 0 1999
7.1.6 The requirements of Section 5.3 shall particularly apply to surfaces around welds, areas of damage
by burning, etc. Contamination shall be removed from all such surfaces which may be over
painted/coated during the repair at these points. This shall be done before surface preparation on
the welds, burns, etc. Overspray from earlier painting/coating operations shall be completely
removed so as to expose any contamination beneath.

7.2 Sweep Blasting

7.2.1 Sweep blasting of existing coatings for the purpose of overcoating shall only be carried out when
approved on a case-by-case basis.

7.2.2 On surfaces subject to patch repair, sweep blasting of coatings to be retained shall not be conducted
at the same time as abrasive blast cleaning of the exposed steel but as a separate activity after
preparation of the steel is complete.

7.2.3 Isolated spot blasting on coated surfaces shall be carried out by means of vacuum recovery systems.

7.3 Priming Delay of Prepared Surfaces

All prepared steel surfaces shall be coated within four hours of the start of surface preparation and
while the surface is still at the approved specified standard.

7.4 Fabrication Welds

Fabrication welds on structural members blast cleaned and primed before fabrication shall be
prepared in accordance with this section.

7.5 Surfaces Primed with Holding Primer

Surfaces primed with holding primer shall be inspected prior to preparation for overcoating. Any
areas of damage, misses, corrosion breakthrough, etc., shall be corrected by abrasive sanding or spot
blast cleaning before applying the principal primer.

8.0 PROCUREMENT AND STORAGE OF PAINT MATERIALS

8.1 Approval

8.1.1 All paints, coatings and other materials shall be in accordance with GES X.03 and approved by the
Owner. Paints containing lead shall not be permitted.

8.1.2 Whenever thinning is necessary, the brand of thinner recommended by the coating manufacturer
shall be used.

8.2 Uniformity of Sourcing

All painting/coating materials applied to a particular item of equipment or group of surfaces shall
be supplied by the same manufacturer unless otherwise approved by the Owner. Seven working
days notice of any proposal to deviate from approved procedures shall be given. Satisfactory
compatibility shall be demonstrated by providing the results of approved testing.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 13 of 21
Rev 0 1999
8.3 Delivery and Shelf Life

Paints/coatings shall be obtained in original, undamaged, manufacturer's containers marked with

product reference, batch numbers and expiry data of shelf life and shall remain unopened until
required for use. Labelling on each container shall comply with Section 8.7 of this specification.
Paints with an expired shelf life shall not be used.

8.4 Condition of Paints

Paints which have deteriorated during storage shall not be used. This includes, but is not limited to,
coatings which have gelled, formed a sediment which cannot be reconstituted, or formed a skin
more than 0.04" (1mm) thick.

8.5 Storage Conditions

Paints/coatings shall be stored in a locked, well-ventilated building, out of sunlight, and in a

location where they do not pose a fire risk to other areas. Temperatures of paint stores shall be
periodically checked for compliance with manufacturer's recommendations.

8.6 Manufacturer's Requirements

The Vendor/Contractor shall conform to all the manufacturer's requirements. Before commencing
work the Vendor/Contractor must be in possession of all of the manufacturer's application sheets
and health and safety information. The requirements of the manufacturer's data sheets shall be
observed in conjunction with the requirements of this specification.

8.7 Standard Labelling

8.7.1 Every drum or tin supplied must possess its own label securely attached to the side of the container.
Each label must include the following information stated clearly and legibly in English:

- Paint/coating name
- Paint/coating description
- Product (container contents) name and identification code
- Product description (including brushing or spraying grade)
- Mixing instructions
- Batch identification code
- Batch manufacture date and shelf life
- Manufacturer's name
- Supplier's name

8.7.2 Each delivery of paint products must be accompanied by four complete sets of all relevant
manufacturer's Data Sheets, application sheets and health and safety information.

8.8 Sampling of Paints/Coatings

8.8.1 For the purpose of assessing paint conformity with the specification, a comparison sample shall be
taken at the point of use.

8.8.2 Where a dispute is likely to arise, after careful mixing, three identical samples shall be taken, one
each for the Owner, the Vendor/Contractor and the manufacturer.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 14 of 21
Rev 0 1999
9.0 PREPARATION OF PAINTING/COATING MATERIALS

9.1 All painting/coating materials shall be prepared in strict accordance with manufacturer's
instructions.

9.2 Single pack paints/coatings supplied in containers of 5 litres or less may be stirred by hand. A
power stirrer shall be used to prepare larger quantities.

9.3 Two pack paints/coatings shall be stirred by mechanical means only. Before mixing, the individual
components shall be thoroughly stirred in their original containers until a uniform consistency is
obtained.

9.4 The manufacturer's stated mixing ratio for two-pack paints/coatings shall be strictly complied with.
Standard units of two-pack paints/coatings shall not be broken down to provide smaller quantities
unless an approved measuring apparatus is used and the process is approved by the Owner.

9.5 Particular attention shall be paid to mixing paint/coatings with heavy pigments, e.g. zinc, to ensure
that the pigments are thoroughly dispersed in the medium prior to application. Such coatings shall
be stirred continuously during application.

9.6 Paints/coatings being prepared in their original containers shall not be transferred until all settled
pigment is incorporated. Part of the material may be poured off temporarily to assist in this process,
but the whole shall finally be blended to a uniform consistency.

9.7 Paints/coatings shall not be mixed or maintained in dispersion by means of an air stream
introduced into the material.

9.8 The contents of containers which have been opened shall be protected from all contamination.

10.0 PAINT/COATING APPLICATION

10.1 General

Painting/coating application shall be in accordance with the paint/coating manufacturer's Data

Sheets.

10.2 Brush Application

10.2.1 Brush applications shall only be considered when the materials concerned are suitable for brush
application and under the following instances:

- for small areas where considerable masking is required, for bolt and rivet heads and very
rough surfaces;
- for the first coat of an inhibitive primer applied direct to the steel surface;
- where toxic or other health hazards preclude spraying;
- when spray application is difficult, due to location of work or wind conditions;
- as an additional stripe coat over all edges, corners and protuberances.

10.2.2 In all cases good quality animal bristle or nylon brushes shall be used for painting, and shall be kept
clean, dry and flexible during use.

10.3 Spray Application

10.3.1 All painting/coating application shall be by airless or air assisted spray as appropriate. Hopper
guns or special two component guns shall be used for certain solvent-free high viscosity
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 15 of 21
Rev 0 1999
paints/coatings.

10.3.2 Hose and containers shall be thoroughly cleaned before the addition of new materials. Fluid hoses
and paint/coating guns should be flushed out with clean solvent whenever a paint/coating material
change is made. Solvents used shall be compatible with both coatings involved in the change.
Cleaning solvents shall be discharged from hoses and guns before spraying begins.

10.3.3 Paint/coatings shall be applied in a uniform layer, with each pass of the spray pattern overlapping
by 50% onto the previous pass. The spray pattern shall be such that the paint/coating is deposited
in a solid, uniform, wet film, free of runs, sags, misses, dry spray, pores and bubbles.

10.3.4 Spray nozzles and tips shall be of the correct size for the paint/coating being applied, in accordance
with the manufacturer's recommendations. Variable spraying tips shall not be used.

10.3.5 The maximum width of spray fan shall be 12" (300mm). Fan widths generally shall be suitable for
the dimensions of the surfaces to be coated.

10.3.6 Spray fans shall be maintained at right angles to the surface being coated, 45° at corners and internal
angles, and at a maximum distance of 12" (300mm) from the surface.

10.3.7 Edges, corners, welds and all areas difficult to coat adequately by spraying, shall receive an extra
coat by brush immediately before the overall spray coat. This does not apply to zinc silicate
primers.

10.3.8 Any runs, sags or bubbles that may form shall immediately be brushed out, or the paint/coating
shall be removed and reinstated.

10.4 Ambient Conditions

10.4.1 Unless permitted by the manufacturer's data sheet, paint/coating shall not be applied when the
relative humidity of the air exceeds 85% or surface temperature is outside the following range:

- below 50°F (10°C);

- above 104°F (40°C);
- less than 5°F (3°C) above the dew point of the surrounding air.

10.4.2 Additionally, unless the work is being performed in an approved enclosure it shall not proceed
when wind is dust laden, during mist or rain, or when any of these conditions are imminent.

10.5 Overpainting/coating

The manufacturer's published over-painting/coating delay times, both minimum and maximum,
shall be strictly complied with.

10.6 Overspray

10.6.1 Over spray or drips shall not be allowed to fall onto surfaces that have already been prepared or
coated. If this occurs, all of the coating on the affected area shall be removed and reinstated.

10.6.2 Particular attention shall be paid, using protective covers, to ensure that zinc containing products do
not over spray or fall onto stainless steel. If this occurs, these products must be removed
immediately by a process that does not require heat.

10.7 Requirements for Zinc-Rich Primers

10.7.1 Zinc silicates shall be sprayed with extreme care to avoid excessive thickness and defects in the film.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 16 of 21
Rev 0 1999
Brushes shall only be used on small areas to correct variations in the wet film thickness.

10.7.2 Welds on sections, plate, tubulars, etc., previously prepared and primed with zinc silicate, and
points of damage requiring repair of zinc silicate primer, shall be blast cleaned in accordance with
Section 5.7 and primed with a two-pack zinc-rich epoxy primer containing at least 90% by weight of
zinc in the dry film.

10.7.3 All necessary steps shall be taken to prevent damage, e.g. by overblast, to surfaces coated with zinc
silicate primer with the aim that surfaces, where specified, shall be uniformly primed with zinc
silicate and not extensively repaired with zinc-rich epoxy. Any surface coated with zinc silicate
which is subject to excessive repair shall be reblasted and repainted.

10.7.4 Zinc silicate primers shall be overcoated within seven days of application, before zinc salts have
begun to form.

10.7.5 Zinc epoxy primers shall be overcoated before zinc salts have begun to form.

10.7.6 Zinc rich primers shall not be applied to hand cleaned or mechanically cleaned surfaces.

10.8 Handling

Painted/coated items shall not be handled or lifted before the paints/coatings are fully cured.
Special precautions shall be taken to avoid any damage to the painting/coating system during
handling.

11.0 REPAIR OF DEFECTS

11.1 Defects Revealed by Blast Cleaning

Defects in the steel surface revealed by blast cleaning shall be remedied to a procedure outlined in
the applicable specifications and re-inspected. The area affected by remedial action shall be
reblasted prior to the application of painting/coating.

11.2 Damaged Substrate

11.2.1 Areas of exposed, damaged substrate shall be prepared by spot blast cleaning.

11.2.2 Surfaces which cannot be blast cleaned due to lack of space for blast nozzles or proximity of
sensitive equipment may be prepared by hand or power tool cleaning.

11.2.3 The damaged area shall be recleaned as originally specified for that item and the full
painting/coating system reapplied in accordance with manufacturer's recommendations.

11.3 Repair of Galvanising

Damage to galvanising shall be repaired by abrasive blast cleaning to SIS 05 5900 Sa 2½ and
recoated to an approved procedure.

12.0 TESTING AND INSPECTION

12.1 General

12.1.1 All surface and paint/coating application inspection methods shall comply with the inspection
guide of BS 5493, Table A1-5.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 17 of 21
Rev 0 1999
12.1.2 Prior to the commencement of any painting/coating activities, the Vendor/Contractor shall submit
an inspection procedure for approval by the Owner. The Inspector shall have the right to inspect the
paint/coatinging operation at any stage and to reject any tools, materials, equipment or work which
do not conform to this specification and the approved procedure.

12.2 Test Equipment

The following approved test equipment shall be provided and maintained at the site of the works by
the Vendor/Contractor:

a) Swedish Photographic Standard SIS 05 5900;

b) surface profile gauge or "press-on" films and micrometer;
c) coating thickness meter (with calibration shims);
d) wet film thickness combs;
e) hygrometer with charts to determine relative humidity (RH)
f) maximum and minimum thermometer;
g) magnetic steel thermometer;
h) flow cup type B, No. 4 to BS 3900 and stop watch;
i) adhesion tester (0-280 Kg/cm²);
j) holiday detector;
k) airline pressure gauge with hypodermic needles.

12.3 Test Methods to be Adopted During Painting/Coating Operations

12.3.1 Surface Preparation (Steel Surfaces)

a) Cleanliness of Surface

This shall be determined by using the colour plates shown in SIS 05 5900.

b) Surface Profile

The approximate amplitude of the surface profile shall be determined using an approved
surface profile gauge to ensure that the profile conforms with the manufacturer's
specification.

12.3.2 Measurement of Relative Humidity and Dew Point

A whirling hygrometer to BS 2842 shall be utilised.

12.3.3 Measurement of Viscosity to Determine the Quantity of Thinners to be added

This procedure shall utilise the flow cup No.4, to BS 3900: Part 6 and a stop watch.

12.3.4 Measurement of Paint/coating and Coating Thickness

(a) Measurement of Wet Film Thickness shall be in accordance with ASTM D1212 and
immediately after application of the paint/coating, the comb-gauge shall be placed on to
the substrate to obtain representative results over the paint/coatinged area.

(b) Measurement of Dry Film Thickness shall be in accordance with ASTM D1186 and D1400.
Generally, dry film thicknesses specified are nominal thicknesses and the average of
readings taken over any square metre of the scheduled area shall equal or exceed the
nominal thickness. No one reading shall be less than 25% or greater than 10% of the
nominal thickness.

(c) For surfaces beneath passive fire protection, total coating thickness shall be within -20%
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 18 of 21
Rev 0 1999
+0% of the sum of the specified thicknesses of the individual coatings.

(d) For systems intended for elevated temperature service, the thickness of silicate, where
present, and/or the thickness of the combined coats of silicone shall be within -20% +0% of
the sum of the specified thicknesses of the individual coatings.

(e) The dry film magnetic type thickness gauge shall be calibrated by the Vendor/Contractor
using foils in the film thickness range being checked and over the type of surface being
paint/coating.

(f) For ferrous surfaces a Magnetic Inspectors Gauge shall be used.

(g) For non-ferrous surfaces a Paint Inspectors Gauge shall be utilised.

(h) As the use of the Paint Inspectors Gauge damages the finished painting/coating, its use
should be limited to the minimum number of measurements required to ensure that the
specified coating thickness is being achieved.

12.3.5 Measurement of Paint and Coating Adhesion

(a) Adhesion of the paint/coating and coating shall be checked at regular intervals using a
"pull off" adhesion tester to ASTM D4541. The surface to be tested shall be degreased and
abraded with emery cloth.

(b) Similar to the Paint Inspectors Gauge, adhesion testers damage the finished coating and use
should be limited to the minimum number of tests required to ensure that specified
adhesion values are being achieved.

12.3.6 Holiday Detection

(a) All painted/coated or coated areas shall be 100% holiday tested in accordance with NACE
RP-01-88. The holiday detector shall be suitably rated for the thickness and di-electric
strength of the coatings under test.

(b) A wet sponge holiday detector shall be used for thin film coatings and paint/coating.

(c) For thicker coatings, rolling spring, flat or circular brushes shall be used as appropriate.

(d) All holidays shall be marked and repaired.

12.3.7 Rejected Work and Equipment

The Inspector shall have the right to reject any and all tools, instruments, materials, staging,
equipment or work which does not conform to the specification or the inspection procedure.
Rejected areas of painting/coating applications shall be marked with a compatible painting/coating
of contrasting colour. Any rejected painting/coating applications, defective preparatory work, e.g.
blast cleaning, staging, or any defective work not conforming to this specification shall be rectified
by the Vendor/Contractor at no additional cost to the Owner. All rejected tools, instruments,
materials, or equipment shall be replaced or rectified at no additional costs to the Owner.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 19 of 21
Rev 0 1999
12.3.8 Approval

The Vendor/Contractor shall notify the Inspector 48 hours before work or part of the work
commences. Prior to the final acceptance of part, or the complete work, an inspection shall be made.
The Vendor/Contractor and the Inspector shall be present, the Vendor/Contractor shall make an
inspection report which shall be signed by both parties.

13.0 HEALTH AND SAFETY

13.1 General

The Vendor/Contractor shall conduct all work in a safe manner at all times.

13.2 Abrasive Blasting

13.2.1 Operators using abrasive blasting equipment shall be adequately protected with fresh air, helmets,
boots, leather aprons and gloves.

13.2.2 Blasting equipment should include a dead man's handle to stop the abrasive flow immediately the
operator releases the nozzle.

13.3 Painting and Coating Operations

13.3.1 Operators shall be in possession of the manufacturer's Health and Safety Data Sheets and shall work
to the stated requirements.

13.3.2 Operations shall be undertaken to eliminate risks with flammable paints/coatings.

13.3.3 Adequate ventilation shall be provided to ensure that fire, explosion and toxicity risks are
minimised.

13.3.4 Face masks and goggles shall be worn for paint/coating spraying.

13.4 Skin Irritants

Precautions shall be taken to prevent skin irritation or dermatitis due to contact with aromatic
solvents, epoxy resins and other known irritants.

14.0 REPORTING

14.1 Status and Progress Report

The Vendor/Contractor shall produce the following report records for all site works:

14.1.1 Daily Reports

a) Paintings/coatings used, areas, and locations treated, wet and dry film thickness.
b) Types of work performed, e.g. blast cleaning, second coat, colour.
c) Problems delaying work, anomalies, progress.
d) Weather Conditions (temperature, RH etc.).
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 20 of 21
Rev 0 1999
14.1.2 Weekly and/or Monthly Reports

a) Percentage of work completed.

b) Target percentage of work.
c) Problem highlights.

14.1.3 Final Report

a) Paints/Coatings used and locations.

b) Paints/Coatings report.
c) Acceptance certificates.

14.2 Completion Records

Before the demobilisation of any of the Vendor/Contractor's equipment and/or personnel from the
work site, a full report on outstanding, incomplete or remedial work shall be submitted to the
Inspector for final approval, to agree percentage completion.

15.0 CLEAN-UP

After painting/coating and inspection have been completed, all plant, scaffolding, equipment,
surplus materials and waste resulting from paint/coatinging work shall be collected and removed
from the working areas. Over-runs, droppings, and smears shall be removed.

16.0 STORAGE OF PAINTED ITEMS

The degradation of coatings on stored steelwork shall be minimised by the adoption of the
following precautions:

16.1 Spacers

Freshly painted/coated surfaces shall not be in contact. Whilst items are in transit or storage
wrappings, packaging or crates shall be adopted. For larger items, timber packing shall be
specified.

16.2 Stacking

The maximum height of stacks shall not be greater than 8ft (2.5m) excluding the thickness of the
support sleepers and the height of the supporting base, the bottom layer being laid on packing
raised above the ground and the rain splash zone.

The size and number of supporting sleepers shall be such as to achieve a uniform load distribution
thus avoiding deformation.

16.3 Handling

The methods of transport and handling during storage and/or whilst on site shall include the
following precautions;

i) lifting lugs or brackets where practicable;

ii) the provision of a special lifting harness, nylon slings, rubber protected chains and chocks,
etc;
iii) methods of loading that will reduce site handling to the minimum;
iv) special supports, packing and lashings, stacking in holds and on decks, to avoid chafing;
v) special wrapping and packaging of transported items.
 GENERAL ENGINEERING SPECIFICATION GES X.01
SURFACE PREPARATION AND PAINTING APPLICATION Page 21 of 21
Rev 0 1999

Table 1 - Dew Point Determination

Dew Points (°C) at Various Relative Humidities

Relative Humidities

Air Temp° 30% 40% 50% 60% 70% 80% 90% 100%

-1 - - - - -6.5 -4 -2 -1
4 - -6.5 -4 -2 0.5 1.5 3.5 4.5
10 -6.5 -3.5 0.5 2 3.5 5.5 8.5 10

15.5 0 2 4 8 10 11.5 14 15.5

21 3 6.5 10 13 15 18 19.5 21

26.5 7 12 15.5 19 21 23.5 25 26.5

32 13 16.5 20.5 24 25.5 28.5 30.5 32

38 18 22 25.5 29 31 33.5 36 38

Notes:

It is essential to ensure that no condensation occurs on blasted steel or between coats during
painting/coating.

Air at a given temperature can only contain a certain (maximum) amount of water vapour. This
proportion is lower at lower temperatures.

The dew point is the temperature of a given air-water vapour mixture at which condensation starts,
since at that temperature its maximum water content (saturation) is reached.

In practice, a safety margin must be adopted, whereby the substrate temperature is at least 5°F (3°C)
above dew point.

S:\NOC9077\ADMIN\SPECIFICATIONS\X-SERIES\X-01\GESX01RF
 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES X.02

COLOUR CODING OF EQUIPMENT AND PIPING

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 2 of 12
Rev 0 1999

INDEX

SEC HEADING PAGE

1.0 SCOPE 3

1.1 Introduction 3
1.2 Other NOC Specifications 3

2.0 DEFINITIONS 3

2.2 Contractual 3

3.0 CODES AND STANDARDS 4

4.0 IDENTIFICATION OF PIPELINES AND SERVICES 4

4.1 General 4
4.2 Colour Coding 5
4.3 Basic Identification Colours 5
4.4 Method of Application 5
4.5 Identification Procedures 5

5.0 DIRECTION OF FLOW 6

6.0 WORDINGS 6

7.0 WARNING OF ELECTRICAL TRACE HEATING 6

8.0 FUNCTIONAL BASIC COLOURS FOR INDUSTRIAL APPLICATIONS 6

Table 1: Basic Identification Colour 7

Table 2: Above Ground Piping Base Colour Classification 8
Table 3: Above Ground Piping Colour Bands 9
Table 4: Equipment and Machinery Base Colour Classification 10
Table 5: Optional Colour Code Indications for General Building Services, Colour
Guide 12
(Extract from BS 1710)
 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 3 of 12
Rev 0 1999
1.0 SCOPE

1.1 Introduction

1.1.1 This specification defines the colour coding criteria for surface facilities, equipment and above
ground piping for the purpose of functional and process identification and safety notification.

1.1.2 This specification applies to onshore oil and gas processing facilities and other onshore oil and gas
installations including items purchased either directly or as a part of a package.

1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exceptions must be authorised in writing by the Owner.

1.1.4 In the event of any conflict between this specification, Data Sheets, coating schedules or with any of
the applicable codes and standards, the Vendor/Contractor shall inform the Owner in writing and
receive written clarification before proceeding with the work.

1.1.5 The application of this specification, where modifications and additions to existing facilities are
carried out, will be at the discretion of the Owner who may decide to continue in the interim with
the existing colours and painting schemes for uniformity and utilisation of stocked paint material.
However, if the complete painting of existing facilities is undertaken then it will be mandatory to
comply with GES X.01, X.02 and X.03.

1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

Where indicated in this specification the following NOC Specifications shall apply:

GES A.06 Site Data

GES X.01 Surface Preparation and Painting Application

GES X.03 External Protection Coatings

2.0 DEFINITIONS

2.1 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and
facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work

 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 4 of 12
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Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment
and facilities have been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verifies that the equipment and facilities have been designed, constructed, inspected
and tested in accordance with the requirements of this specification and the Purchase
Order/Contract.

3.0 CODES AND STANDARDS

The following codes and standards shall form an integral part of this specification.

British Standards

BS 1710: Identification of Pipelines and Services

BS 5252: Framework for Colour Co-ordination for Building Purposes

4.0 IDENTIFICATION OF PIPING AND SERVICES

4.1 General

The overall top coat colour for piping and above ground pipelines shall be white to BS 5252 00E55
unless otherwise indicated in this specification. Pipe colour banding shall be applied over the
standard top coat colour to identify the fluid being conveyed.

a) Process plant pipework shall be colour banded for identification to the general
requirements of BS 1710.

b) Colours shall be Owner approved paints, compatible with the main paint system to GES
X.03 or approved coloured tapes.

c) Where banding is adopted, the decorative or protective colour of the pipe shall not be any
of the basic identification colours. In these cases a white base coat shall be used.

d) The basic identification (for banding) shall be adopted at pre-selected locations (maximum
separation between piping/pipeline identification shall be 65ft (20m) and at any other place
where identification is necessary. In particular, the following locations shall be clearly
marked:

- junctions;
- manifolding, platforming and skid limits;
- any major change of directions;
- connections of pipe to vessels, equipment, valves etc.

4.2 Colour Coding

 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 5 of 12
Rev 0 1999

This specification incorporates the three main methods of colour identifications;

a) basic identification colours;

b) basic identification colour and code indications;
c) basic identification colour used in conjunction with the Manufacturer's particular colour
coding scheme.

4.3 Basic Identification Colours

The appropriate basic colour shall be in accordance with BS 1710 as listed in Table 1. Unless
otherwise approved, BS 1710 shall be used to identify the colours for purposes of specifying and
ordering.

Alternative manufacturers painting systems shall be Owner approved and provide an exact match
of colour.

4.4 Method of Application

The basic fluid identification colour shall be by one of the following:

a) painted on the pipe over the whole length (only for certain key utilities);

b) painted or taped on the pipe as a band at points specified in Section 4.1 (d); for width of
band see following recommendations:

Pipe size, dia. Width of band, mm

24", 20", 18", 16" 300mm

14", 12" 150mm
10", 8" 100mm
6" 75mm
4" 50mm
3", 2½", 2" 25mm
1½", 1" 20mm

c) for small facilities where line space is limited between valves and flanges, the lines shall be
adequately marked with painted or taped colour coded bands so that the bands shall be
visible from each valve and flange.

4.5 Identification Procedures

All pipework regardless of bore size, shall be identified by colour banding on the pipe before
insulation is applied, as well as on the insulation cladding.
 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 6 of 12
Rev 0 1999
5.0 DIRECTION OF FLOW

When it is necessary to know the flow direction, the flow shall be shown by an arrow, located
adjacent to base band, of a white or black colour (to contrast with the background colour) by means
of painting. Arrows shall be 6-8" (150-200mm) long x 1" (25mm) wide at the base of the head and
tail and surrounded by a contrasting background 3/8" (10mm) longer and wider than the arrow.

6.0 WORDINGS

If and where deemed necessary, the wordings, consisting of chemical name or formula or
conventional designation of the substance conveyed, shall be painted on beside the bands in the
most suitable locations to ease reading.

7.0 WARNING OF ELECTRICAL TRACE HEATING

The cladding on insulated, electrically traced pipework shall be marked in accordance with BS 5378
to warn of the presence of electrical conductors under the insulation.

8.0 FUNCTIONAL BASIC COLOURS FOR INDUSTRIAL APPLICATIONS

The basic identification colours as per Table 1, shall be adopted for surface facilities and plant
applications:

The colours shown are referred only to finish coats without taking into account the coating system
and the application method.

For particular services or for appearance requirements, the colour of finish coats may be different
from that shown in Table 1. In such cases, colour identification reference shall be made to Tables 2 -
4.

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 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 7 of 12
Rev 0 1999
TABLE 1

Basic Identification Colour

Application Colour Approximate

BS 5252
Designation

Steel Structures, vessel supports Medium Grey 10 A07

Cable-Holding Piping, Containers and Boxes Sky Blue 20 C33
(Cases) for Explosion Proof Units,Raceways for
Cables

Vessels, Columns, Towers, Air Coolers, Tanks, White 00 E55

Spheres, Heat Exchangers

Turbines, Turbo-Compressors, Internal Combustion Light Grey 10 A03

Engines, etc and their base plates

Machine Tools Light Green 14 D43

Electric Rotary Machines: Electric Motors, Sky Blue 20 C33

Alternators (Excluding Transformers, Power
Reactors)

Electric Static Machines: Transformers, Power Light Grey 10 A03

Reactors, etc Silver/Aluminium 02 A03

Switchboards for Control and Protection Light Grey 10 A03

Medium Grey 10 A07

Electrical Power Panels for Control and Protection Focal Green 12 C39
Light Green 14 D43
 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 8 of 12
Rev 0 1999

TABLE 2

Above Ground Piping Base Colour Classification

Piping Colour Approximate Colour of

BS 5252 Lettering and
Designation Arrow

All Process Piping White 00 E55 Black

Acid and Violet 22 D45 Black

Alkalis/Corrosives/Toxi
cs

Glycols, Chemical Black 00 E53 White

Reagents, Liquid
Catalyst

Steam (Uninsulated Light Grey 10 A03 Black

Lines)

Relief Lines and Aluminium 02 A03 Black

Headers, Superheated
Water and Steam
(Insulated Lines)

Treated Water Green 12 E55 Black

Potable Water Blue 18 E53 White

Fire Water and Foam Signal Red 04 E55 White

Piping

Lube Oil Tan 06 C37 White

Fuel Oil, Diesel, Jet Fuel Brown 06 D45 Black

Gaseous Fuels Yellow 10 E55 Black

Air Lines Blue 20 C37 White

Inert Gases Sky Blue 20 C33 White

Nitrogen, Carbon
Dioxide etc.
 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 9 of 12
Rev 0 1999

TABLE 3

Above Ground Piping Colour Bands

Fluids/Service Conditions Colour Banding BS 1710/ BS 4800

Designation

General Service Applications

Hydrocarbon Liquids or Mixed

Phases

Sweet Brown 06 D45

Sour Brown/Orange 06 D45/08 E55

Hydrocarbon Gases

Sweet Yellow 10 E55

Sour Yellow/Orange 10 E55/08 E55

Optional Colour Bands

Utilisation

Water
Green 12 E55
Sea Water Supply/Return Green/Ochre 12 E55/08 D43
Cooling Water Supply Green/Orange 12 E55/08 E55
Desalinated Water Deep Blue 20 E56
Potable Water Green/Brown 12 E55/06 D45
Utility Water Green/Yellow 12 E55/10 E55
Condensate Water

Steam
Medium Grey 10 A07
HP, MP, and LP

Air
Light Blue 18 D41
Instrument Black 00 E53
Plant Blue/Black 18 E53/00 E53
Process (Utilities)

Other Chemicals
Green/Brown 12 E55/06 C39
Ammonia (Liquid and Vapour)
Brown/Red 06 C39/04 E55
Caustic Soda Black/White/Black 00 E53/00 E55/00 E53
Liquid Sulphur
Purple 24 C39
Corrosive and Dangerous Violet 22 D45
Chemicals
Other Fluids Yellow/Black 10 E55/00 E53
Diagonal stripes
DANGER MARKING 75mm wide
 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 10 of 12
Rev 0 1999
Signal Yellow 10 E55
Signal Green 12 E55
Hazardous Substances/Fluids
Non-Hazardous
Substances/Fluids
 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 11 of 12
Rev 0 1999
TABLE 4

Equipment and Machinery Base Colour Classification

Equipment and Machinery Colour Approximate

BS 5252 Designation

Compressors Light Grey 10 A03

Separators White 00 E55

Desalters White 00 E55

Engines, Gas Regulators Light Grey 10 A03

Boilers, Gas Meters Grey 00 A09

Stacks, Chimneys and Flues White 00 E55

Heat Exchangers White 00 E55

Normal Service

Heat Exchangers Silver/Aluminium 02 A03

High Temperature Service

Knock Out Drums White 00 E55

Pumps Deep Bronze 12 C39

Electrical Motors Middle Bronze 12 C37

Vessels White 00 E55

Coolers White 00 E55

Generators Orange 08 E55

Air Receivers White 00 E55

Gas Scrubbers White 00 E55

Dehydration Vessels White 00 E55

Circulating Pumps Light Grey 10 A03

Other Rotating Equipment

Horizontal Tanks
Diesel Fuel White 00 E55
Lube Oil Tan 06 C37

Tanks-Cone Roof
Gasoline Naphtha, Solvent (Roof White 00 E55
and Upper Shell)
Diesel Oil, Heating Oil White 00 E55
(Roof and Upper Shell)
Residual Black Oils Black 00 E53
Other Products Black 00 E53
(Bottom Shell Band)
 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 12 of 12
Rev 0 1999
TABLE 4 cont.

Equipment and Machinery Colour Approximate Other usage

BS 5252 Notes
Designation

Spheres and Spheroids Tanks

Shell White 00 E55

Spheroid Skirt Black 00 E53
Fireproofed Sphere Lids Not to be Painted

Open Top Floating Roof Tanks

(Crude)

Shell White 00 E55 Upper courses up

Bottom Band Black 00 E53 to 1220mm Rim
Roof Black 00 E53
Wind Girders White 00 E55

Oil (Lube Tanks) Tan 06 C37

Wellheads and Christmas Trees Black 00 E53

Tank and Vessels Interiors Black 00 E53 Black Coal Tar

Epoxy

Treated Water Storage Tanks White 00 E55 Any Process

Potable Water Storage Tanks White 00 E55

Fire Water Storage Tanks White 00 E55

Enclosures/Transformers Light Grey 10 A03

Constructions

Platforms (Steel Frame, Stairs, Yellow 10 E53

Plates, cages)
Ladders/Walkways/Handrails Yellow 10 E53
Pedestals/Bases/Skids Black 00 E53
Concrete Floors Olive Green 10 C39
Tank Valves/Control Valves Silver/ 02 A03
Engine Exhaust Aluminium 02 A03
Silver/
Aluminium

Cathodic Protection Devices Orange 06 E51

Fire Sheds Red 04 E55
 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 13 of 12
Rev 0 1999
TABLE 5

Optional colour code indications for general building services (colours are given for guidance.
When specifying colours the colour references given in Tables 1, 2 and 4 of BS 1710 shall be
stated).

Colour Guide (Extract from BS 1710)

Fluids Pipe Basic Basic Colour Code Colour Code Indication Colour Code Indication
Contents Identification Indication BS BS BS 1710/BS 5252
Colour (approx 1710/BS 5252
150mm)

Water:

Drinking Green 12 D45 Auxiliary Blue 18 E53

Cooling (primary) Green 12 D45 White 00 E55

Boiler Feed Green 12 D45 Crimson White Crimson 04 D45 00 E55 04 D45

Condensate Green 12 D45 Crimson Emerald Crimson 04 D45 14 E53 04 D45

Green

Chilled Green 12 D45 White Emerald White 00 E55 14 E53 00 E55

Green

Cold, down service Green 12 D45 White Blue White 00 E55 18 E51 00 E55

Hot Water Supply Green 12 D45 White Crimson White 00 E55 04 D45 00 E55

Hydraulic Power Green 12 D45 Salmon Pink 04 C33

Diesel fuel White Brown

Furnace fuel Brown

Lubricating Emerald Green Brown

Hydraulic Power Salmon Pink Brown

Transformer Crimson Brown

Other
suggestions:

Natural gas Primrose Yellow ochre

Vacuum White Light Blue

Compressed Air Light Blue

Drainage Black

Steam Silver grey

Electrical Conduits Orange

Ventilation Ducts

Acid and Alkalis Violet

Anhydrous Dark Mauve (02 Yellow ochre

 GENERAL ENGINEERING SPECIFICATION GES X.02
COLOUR CODING OF EQUIPMENT AND PIPING Page 14 of 12
Rev 0 1999
Ammonia C37 )

Other refrigerants* Emerald Green

Refrigerant Blue Yellow ochre

(proposed)*

Refrigerant Sea Green (16 C37) Yellow ochre

(proposed)*

Refrigerant Golden Brown (06 Yellow ochre

(proposed)* D45)

*Note: The nature of the contents of refrigeration service pipe should be indicated by the chemical
symbol and the refrigerant number where appropriate as specified in BS 4580.

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 NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES X.03

EXTERNAL PROTECTIVE COATINGS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 2 of 20
Rev 0 1999

INDEX
SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Other NOC Specifications 3

2.0 DEFINITIONS 3

2.1 Technical 3
2.2 Contractual 3

3.0 CODES AND STANDARDS 4

4.0 COLOUR CODING OF EQUIPMENT AND PIPING 5

5.0 COATINGS SCHEDULES FOR NEW WORKS 5

5.1 General 5
5.2 Coating Schedules 7

6.0 COATINGS OF ITEMS FOR STORAGE OR HOLD 12

6.1 General 12
6.2 Temporary Protection of Smaller Items 12
6.3 Temporary Protection of Larger Items 13

7.0 MAINTENANCE COATINGS 16

7.1 General 16
7.2 Coating Compatibility 16
7.3 Existing Coating Condition 16
7.4 Overcoating Existing Systems 17
7.5 Upgrading of Overcoating 17
7.6 Coating Schedules for Maintenance Works 18
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 3 of 20
Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for external protective painting/coating
schedules for new and existing works for refineries, onshore oil and gas installations and processing
facilities including items purchased either directly or as a part of a package.

1.1.2 This specification also includes painting/coating schedules pertinent to industrial buildings
associated with plants and stations.

1.1.3 The painting/coatings shall comply fully with the provisions laid down in this specification. Any
exceptions must be authorised in writing by the Owner.

1.1.4 In the event of any conflict between this specification and the Data Sheets, or with any of the
applicable codes and standards, the Vendor/Contractor shall inform the Owner in writing and
receive written clarification before proceeding with the work.

1.1.5 Surface preparation, painting application, quality assurance and colour coding, etc, are covered in
GES X.01 and X.02. These documents together with this General Engineering Specification will form
part of the Purchase Order/Contract.

1.2 NOC Specifications

The following NOC specifications are an integral part of this specification and any exceptions shall
be approved in advance by the Owner:

GES X.01 Surface Preparation and Painting Application

GES X.02 Colour Coding of Equipment and Piping

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Coatings

All paints and coatings shall be referred to herein as "Painting/Coatings".

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and
facilities.

Vendor

The company supplying the equipment and material.

Contractor
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 4 of 20
Rev 0 1999

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment
and facilities have been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verifies that the equipment and facilities have been designed, constructed, inspected
and tested in accordance with the requirements of this specification and the Purchase
Order/Contract.

3.0 CODES AND STANDARDS

The design shall comply with this specification and the following Codes and Standards. Unless
specified otherwise in the Purchase Order/Contract, the latest editions of codes and specifications at
the time of the order shall apply.

The following Codes and Standards, together with the references therein, shall be deemed to form
part of this specification. All recommendations shall apply unless specifically modified herein.

BS - British Standards

BS 410 Specification for Test Sieves

BS 1133 Packaging Code Temporary Protection of Metal Surfaces Against Corrosion During
Transport and Storage - Cleaning and Drying of Metal Surfaces

BS 1796 Methods of Test Sieving

BS 4164 Specification for Coal Tar Hot Based Applied Coating Materials for Protecting Iron and
Steel including a Suitable Primer

BS 5493 Code of Practice for Protective Coating of Iron and Steel Structures from Corrosion

ASTM - American Society for Testing and Materials

ASTM, Section 06.01 Paint Tests for Formulated Products and Applied Coatings

SSPC - Steel Structures Painting Council

SSPC, Volume 1 and 2 Steel Structures Paint Manual

 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 5 of 20
Rev 0 1999
3.1.3 German DIN Standards

DIN 55928 Corrosion Protection of Steel Structures by the Application of Organic or Metallic
Coatings.

4.0 COLOUR CODING OF EQUIPMENT AND PIPING

Unless otherwise specified the colour coding of equipment and piping shall be as follows:

4.1 All basic colours for industrial applications and identification colour coding shall comply with GES
X.02.

4.2 Alternative manufacturer's colour coding schemes shall be Owner approved and the exact shade of
colour shall be provided.

4.3 Coating compositions shall be in accordance with this specification.

5.0 PAINTING/COATINGS SCHEDULES FOR NEW WORKS.

5.1 General

5.1.1 Table 1 indicates the painting/coating schedules that shall be applied for varying service
conditions, different substrates and differing degrees of protection. The details of each schedule are
listed after Table 1. Any requirements for painting/coating outside the limits given in the Table 1
shall be brought to the attention of the Owner and clarification sought, prior to any work
commencing.

5.1.2 The Vendor/Contractor shall prepare the surface and apply the specified primer and finish coats as
a complete system and shall not substitute or intermix products from different manufacturers.

5.1.3 Where the Vendor/Contractor wishes to select a different painting/coating to the one listed, the
Owner's prior approval shall be obtained.

5.1.4 The indicated temperatures are maximum operating surface temperatures.

5.1.5 The items listed are not necessarily a complete list of all items to be printed/coated. Some items
have both insulated and uninsulated sections or have both hot and cold sections. Each section must
be coated as specified.

5.1.6 For heat exchangers, columns, compressors and similar equipment, the higher of the inlet or outlet
temperature on the side under consideration shall be used in determining the applicable
painting/coating schedule.
 GENERAL ENGINEERING SPECIFICATION GES X.03
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Rev 0 1999
TABLE 1 - PAINTING/COATING SCHEDULES FOR EXTERNAL SURFACES

Operating temp oC Painting/coating Schedule

Number

ITEMS TO BE COATED From To Uninsulated Surfaces to be

surfaces Insulated

Carbon steels and low alloy (<9% Cr) steels

a) Vessel exchanger, equipment, piping, storage -45 Below - 9

tanks and structural steel with the exception of ambient
items specifically listed below (Note 4)

Ambient 93 2 1

94 200 3 1

201 400 4 1

401 538 5 5

b) Structural steel to be fireproofed (Note 6) Ambient 93 6 -

c) Buried tanks and piping Ambient 93 7 -

Storage tank plates

a) Exterior surfaces of plates (non-process sides) Ambient 93 8 -

requiring temporary protection (Note 7)

b) Process side of tank plates (Note 5) Ambient 93 10 -

c) Floor plate surfaces which will be in contact with Ambient 93 7 -

soil (Notes 2 and 8)

Galvanised surfaces (notes 1 and 3)

a) Items e.g. ladders, ladder cages, handrails, cable Ambient 93 11 -

trays (not fireproofed), etc., to be painted

Stainless steels

a) All items exposed to cryogenic conditions (Note -196 Below 12 12 (Note 7)

4) ambient

b) All items exposed to atmosphere Ambient 93 13 12

94 200 14 14

Aluminium and its alloys

a) All items exposed to plant outside environment Ambient 93 13 -

Concrete, Architectural surfaces etc

a) Interior and exterior painting/coating for Ambient Ambient 15

concrete

b) Painting/coating for plaster, plasterboard and Ambient Ambient 16

gypsum based surfaces

c) Fire retardant painting/coatings for timber and Ambient Ambient 17

hardboard

d) Paint painting/coatings for protection and Ambient Ambient 18

 GENERAL ENGINEERING SPECIFICATION GES X.03
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Rev 0 1999
decorative appearance of timber and hardboard

e) Varnish painting/coatings for timber and Ambient Ambient 19

hardboard
 GENERAL ENGINEERING SPECIFICATION GES X.03
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Rev 0 1999
Notes:

1. Open galvanised gratings unless otherwise specified shall not be painted.

2. Tank floor plate shall be masked off 100mm from the edge to prevent painting/coating
application. Surfaces coated on the soil side shall be holiday tested and repaired, if
necessary, before installation.

3. For items supplied with galvanising, all galvanised surfaces exposed to atmosphere must
be top coated with system 13.

4. Vendor shall be required to certify painting/coating acceptability for low temperature

where applicable.

5. After tank erection, the entire tank shall be blasted cleaned and paint/coat shall be applied.

6. System subject to approval by fire proofing material supplier.

7. Vendor/Contractor shall take appropriate action to avoid corrosion of plates during storage
and erection.

8. The application of tar based paints may, under certain conditions, pose a risk to health. The
Vendor/Contractor shall ensure that the health and safety data sheets provided by the
manufacturer are strictly observed.

5.2 Painting/Coating Schedules

Painting/Coating Schedule 1

Applicable Substrate: Carbon Steel

Surface Preparation: Sa 2½
Surface Profile: 20 -35µm

Primer Coat: Alkyl zinc silicate primer (75m)

Interim Coat: None
Finish Coat: None

Total Dry Film Thickness: (75µm)

Maximum Temperature Resistance: 400 °C

Painting/Coating Schedule 2

Applicable Substrate: Carbon Steel

Surface Preparation: Sa 2½
Surface Profile: 50 -75µm

Primer Coat: Zinc rich epoxy primer (50µm)

Interim Coat: Polyamide epoxy (125µm)
Finish Coat: Recoatable Polyurethane (75µm)

Total Dry Film Thickness: (250µm)

Maximum Temperature Resistance: 93°C
 GENERAL ENGINEERING SPECIFICATION GES X.03
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Rev 0 1999
Painting/Coating Schedule 3

Applicable Substrate: Carbon Steel

Surface Preparation: Sa 2½
Surface Profile: 50 -75µm

Primer Coat: Alkyl zinc silicate primer (75µm)

Interim Coat: Silicon Acrylic (30µm)
Finish Coat: Silicon Acrylic (30µm)

Total Dry Film Thickness: (135µm)

Maximum Temperature Resistance: 200°C

Painting/Coating Schedule 4

Applicable Substrate: Carbon Steel

Surface Preparation: Sa 2½
Surface Profile: 50 -75µm

Primer Coat: Alkyl zinc silicate primer (75µm)

Interim Coat: Silicon Aluminium (25µm)
Finish Coat: Silicon Aluminium (25µm)

Total Dry Film Thickness: (125µm)

Maximum Temperature Resistance: 400°C

Painting/Coating Schedule 5

Applicable Substrate: Carbon Steel

Surface Preparation: Sa 2½
Surface Profile: 50 -75µm

Primer Coat: Silicon Aluminium (25µm)

Interim Coat: -
Finish Coat: Silicon Aluminium (25µm)

Total Dry Film Thickness: (50µm)

Maximum Temperature Resistance: 538°C

Painting/Coating Schedule 6

Applicable Substrate: Carbon Steel

Surface Preparation: Sa 2½
Surface Profile: 50 -75µm

Primer Coat: Zinc rich epoxy primer (50µm)

Interim Coat: Polyamide MIO epoxy (125µm)
Finish Coat: -

Total Dry Film Thickness: (175µm)

Maximum Temperature Resistance: 93°C

Painting/Coating Schedule 7
 GENERAL ENGINEERING SPECIFICATION GES X.03
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Rev 0 1999
Applicable Substrate: Carbon Steel
Surface Preparation: Sa 2½
Surface Profile: 75-100µm

Primer Coat: Polyurethane tar (750µm)

Interim Coat:
Finish Coat: Polyurethane tar (750µm)

Total Dry Film Thickness: (1500µm)

Maximum Temperature Resistance: 93°C

Painting/Coating Schedule 8
Applicable Substrate: Carbon Steel
Surface Preparation: Sa 2½
Surface Profile: 50 -75µm

Primer Coat: Alkyl zinc silicate primer (25µm)

Interim Coat: -
Finish Coat: -

Total Dry Film Thickness: (25µm)

Maximum Temperature Resistance: 93°C

Painting/Coating Schedule 9

Applicable Substrate: Carbon Steel and Stainless Steel

Surface Preparation: Sa 2½ for carbon steel see GES X.01 for stainless steel
Surface Profile: 50 -75µm for carbon steel see GES X.01 for stainless steel

Primer Coat: Polyamide epoxy primer - must be zinc free (50µm)

Interim Coat: Polyamide MIO epoxy (100µm)
Finish Coat: Polyamide MIO epoxy (100µm)

Total Dry Film Thickness: (250µm)

Maximum Temperature Resistance: 93°C

Painting/Coating Schedule 10

Applicable Substrate: Carbon Steel

Surface Preparation: Sa 2½
Surface Profile: 50 -75µm

Primer Coat: Pure epoxy (200µm)

Interim Coat: -
Finish Coat: Pure epoxy (200µm)

Total Dry Film Thickness: (400µm)

Maximum Temperature Resistance: 93°C

Painting/Coating Schedule 11

Applicable Substrate: Galvanised Surfaces

Surface Preparation: Sa 2½
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 11 of 20
Rev 0 1999
Surface Profile: should not completely remove the zinc surface and should be in the range, 20-30µm

Primer Coat: Polyvinyl butyryl wash (10µm)

Interim Coat: Polyamide MIO epoxy (40µm)
Finish Coat: Recoatable Polyurethane (75µm)

Total Dry Film Thickness: (125µm)

Maximum Temperature Resistance: 93°C

Painting/Coating Schedule 12

Applicable Substrate: Stainless Steel

Surface Preparation: See GES X.01
Surface Profile: See GES X.01

Primer Coat: Polyamide epoxy primer - must be zinc free (50µm)

Interim Coat: Polyamide epoxy (125µm)
Finish Coat: Polyamide epoxy (125µm)

Total Dry Film Thickness: (300µm)

Maximum Temperature Resistance: 93°C
Minimum Temperature Resistance: -196°C

Painting/Coating Schedule 13

Applicable Substrate: Stainless Steel, Aluminium and Aluminium alloys

Surface Preparation: See GES X.01
Surface Profile: See GES X.01

Primer Coat: Polyamide epoxy primer - must be zinc free (50µm)

Interim Coat: Polyamide epoxy (125µm)
Finish Coat: Recoatable Polyurethane (75µm)

Total Dry Film Thickness: (250µm)

Maximum Temperature Resistance: 93°C

Painting/Coating Schedule 14

Applicable Substrate: Stainless Steel

Surface Preparation: See GES X.01
Surface Profile: See GES X.01

Primer Coat: Flakeglass vinyl ester (600µm)

Interim Coat: Polyamide epoxy (125µm)
Finish Coat: Polyurethane (75µm)

Total Dry Film Thickness: (600µm)

Maximum Temperature Resistance: 200°C

Painting/Coating Schedule 15

Applicable Substrate: Interior and exterior painting/coating for concrete.

Surface Preparation: Brush clean, remove white deposits and laitence with a wire brush as necessary.
Sweep blasting is also permitted. Fill obvious voids and cracks with a proprietary concrete filler and sand.
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 12 of 20
Rev 0 1999
Grind back to a flush finish. Large scale porosity, spalling or exposure of reinforcement should be reported
to the Owner for action. Wash with low chloride content, preferably potable quality water, and allow to dry.
On clean surfaces the wash may be omitted if authorised by the Owner.

Primer Coat: Proprietary sealer (absorbed into concrete)

Interim Coat: High build vinyl emulsion (75µm)
Finish Coat: As intermediate (external surfaces only)

Total Dry Film Thickness: (75-150µm)

Maximum Temperature Resistance: Ambient

Painting/Coating Schedule 16

Applicable Substrate: Plaster, plasterboard and gypsum based surfaces.

Surface Preparation: Brush clean, wipe of grease and dirt with solvent or water based detergent if required.
Wash with detergent in clean water

Primer Coat: Proprietary Sealer (plaster less than 8 weeks old)

Interim Coat: -
Finish Coat: Vinyl Emulsion

Total Dry Film Thickness: To a thickness sufficient to provide a uniform colour

Maximum Temperature Resistance: Ambient

Painting/Coating Schedule 17

Applicable Substrate: Interior timber, hardboard and plywood.

Surface Preparation: See GES X.01

Primer Coat: Alkyd wood primer

Interim Coat: Fire retardant, alkyd wood undercoat
Finish Coat: Fire retardant finish alkyd.

Total Dry Film Thickness: N/A however interim and finish coats to be of sufficient thickness to hide
preceding coat.
Maximum Temperature Resistance: To manufacturer's recommendations.
 GENERAL ENGINEERING SPECIFICATION GES X.03
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Rev 0 1999
Painting/Coating Schedule 18

Applicable Substrate: Paint painting/coatings for protection and decorative exterior and interior timber,
plywood and hardboard.
Surface Preparation: See GES X.01

Primer Coat: Alkyd wood primer

Interim Coat: Alkyd wood undercoat
Second interim Coat: Alkyd wood undercoat
Finish Coat: Alkyd wood finish

Total Dry Film Thickness: N/A however interim and finish coats to be of sufficient thickness to hide
preceding coat.
Maximum Temperature Resistance: Ambient

Painting/Coating Schedule 19

Applicable Substrate: Varnish painting/coatings for exterior and interior timber, plywood and hardboard
where protection and decorative `natural' appearance is required.
Surface Preparation: See GES X.01

Primer Coat: Spirit base stain compatible with polyurethane varnish if required.
Interim Coat: Clear polyurethane
Finish Coat: Clear polyurethane

Total Dry Film Thickness: Uniform coverage only required.

Maximum Temperature Resistance: Ambient.

6.0 PAINTING/COATINGS OF ITEMS FOR STORAGE OR HOLD

6.1 General

6.1.1 Temporary protection shall be applied to items of equipment which are manufactured on site for
future use, or items ordered from overseas requiring protection during transportation and/or
subsequent storage.

6.1.2 Items for general storage or transit shall also be protected from mechanical damage.

6.1.3 Items for storage in coastal areas or involving ocean shipment shall be protected from exposure to
sea water/moisture and stored off the ground and at an incline to promote water run off by the use
of racks or pallets. Adequate ventilation shall be allowed within all storage containers and
packages.

6.1.4 Items for storage or transit in desert environments shall be protected from direct sunlight and dust
by adequate heat reflecting covers.

6.1.5 The protective finishes are not mandatory in a controlled environment.

6.2 Temporary Protection of Smaller Items

6.2.1 The temporary protection of smaller items shall be undertaken in accordance with BS 1133, Section
6. General guidance requirements are presented in Table 2.
 GENERAL ENGINEERING SPECIFICATION GES X.03
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Rev 0 1999
6.3 Temporary Protection of Larger Items

6.3.1 Tanks and Vessels on Site

(a) If finish painting/coating cannot proceed immediately then large on-site tanks and vessels
shall be externally blast cleaned and coated overall with a holding primer as per schedule.

(b) Holding of on-site tanks and vessels in the part painted or unpainted condition for periods
in excess of ten weeks shall not be permitted. Finish painting/coating shall be completed
within such time.

6.3.2 Small Tanks and Containers

Small tanks and containers for storage in sheltered conditions shall be treated as per Section 6.3.1 or
alternatively shall be externally coated with a wax based temporary protective and sealed.

6.3.3 Skid Mounted Equipment

These items shall be finish painted and stored in open shed conditions protected from excessive
dust and sand storms. All openings should be sealed and machined surfaces shall be protected with
anti-corrosive grease.

6.3.4 Rotating Equipment and Valves

All items shall be treated as Section 6.0, BS 1133.

6.3.5 Mechanical and Vendor Supplied Equipment

These items should normally be stored or transported in the finish painted condition. Exposed
moving parts, nozzles, intakes exhausts and sensitive areas should be masked to prevent ingress of
dust or moisture. Machined surfaces should be coated with a suitable grease or other approved
temporary protection.

6.3.6 Pipework

(a) Pipework shall not be coated for storage, it should be subject to the general requirements of
Section 6.1 of this specification.

(b) Stainless steel piping and tubing should be stored in sheltered conditions.

6.3.7 Structural Steel and Ferrous Components

(a) Structural steel shall be abrasive blast cleaned to SIS 05 5900 Sa 2½ and coated with a
holding primer for storage or transit.

(b) Forgings or casting should be subject to the general requirements of Section 6.1, and
temporary protective painting/coatings are not normally required.

6.3.8 Fasteners

Fasteners, nuts, bolts, and screws accompanying larger items during storage or transportation shall
be coated with a wax based, temporary protective and stored in sheltered conditions.
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 15 of 20
Rev 0 1999
6.3.9 Aluminium

Aluminium items shall be etch primed or treated with an approved temporary protective for
storage or transport.

TABLE 2: SUMMARY GUIDE - SELECTION OF TEMPORARY PROTECTIVES

Type of Article Characteristics of Article Temporary Protective

Simple Parts Small articles packed in quantity (where individual 1. Oil film type (TP 6a) supplemented by
wrapping is impracticable), e.g. nuts, bolts, etc outer wrapping
2. Volatile corrosion inhibitors (TP9)

Parts of simple geometric shape TP 1, TP 2, TP 3, TP 4a, TP 5, TP 6a, TP 7, TP 8, TP 9,

TP 10
TP 10 contact inhibitor is for special application for
certain ferrous metal and zinc items

Articles water-wet after cleaning or manufacture Water displacing, solvent deposited types (TP 1C, TP
2b)

Metal parts with rubber attached Castor oil grease (TP 4b)

Articles without any of the characteristics given 1. Hard film, solvent deposited type (TP 1a,
above, e.g. simple hand tools, gear wheels, 1b)
crankshafts, etc. 2. Soft film, solvent deposited type (TP 2a)
3. Grease type if a drying time is
unacceptable (TP 4a or TP 5)
4. Strippable painting/coating hot or cold
applied types (TP 7 and TP 8)
5. Volatile corrosion inhibitor (Type TP 9)

Assemblies Articles of low degree of complexity with large Grease (TP 4a) on working surfaces and in crevices,
proportion of simple surface then whole article coated with solvent deposited
protective (TP 1a, 1b, TP 2 and TP 8)

Articles with internal surfaces difficult of access. Oil film type (TP 6a) supplemented by water vapour
Lubricating oil systems resistant barrier

Delicate mechanisms 1. Oil film type (TP 6a) supplemented by

water vapour resistant barrier
2. No temporary protective, water-vapour
resistant package with desiccant

Oily or greasy material not tolerable 1. No temporary protective, water-vapour

resistant package with desiccant
2. Volatile corrosion inhibitor (TP 9) with
sealed package

Metals parts with rubber attached Castor oil grease (TP 4b)

Articles without any of the characteristics given 1. Soft, thick film type (TP 3) where dipping
above. is not appropriate
2. Grease type (TP 4a) where hand
application is not practical or no heat is
available
3. Soft film semi-fluid type (TP 5) where free
application is required on large articles
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 16 of 20
Rev 0 1999
4. No temporary protective, water-vapour
resistant package with desiccant.

Especially valuable simple parts or assemblies, particularly having Strippable painting/coating (hot applied) (TP 7)
precision external surfaces

The types of temporary protectives indicated in Table 2 are described briefly below.

Type TP 1 Hard film, solvent-deposited, consisting of solutions of protectives such as suitably

plasticized resins in volatile solvent and generally applied by dipping or spraying.
On evaporation of the solvent a thin hard film of protective remains. There are
three grades:

TP 1a quick drying
TP 1b slow drying
TP 1c slow drying, water displacing

Grade TP 1c is a variety of TP 1b having water displacing properties. It can therefore be

used to protect wet articles without previous drying by more conventional means.

Type TP 2 Soft film, solvent deposited, consisted of solutions of protectives such as lanolin in
volatile solvent and applied by dipping or spraying. On evaporation of the solvent
a thin soft film of protective remains. There are two grades:

TP 2a ordinary grade
TP 2b water displacing grade

Type TP 2b has water displacing properties similar to those referred to in TP 1c above.

Type TP3 Soft film, hot dipping, giving a thick soft film of protective usually based on
Petrolatum (sometimes called petroleum jelly or mineral jelly).

Type TP4 Soft film grease, normally applied by brushing or smearing to give a thick soft film.
There are two grades:

TP 4a metallic soap mineral oil base grease

TP 4b castor oil base grease

Type TP 4a is a conventional type grease used as a protective while TP 4b is a grease of

special composition for application to metal parts to which rubber is attached.

Type TP5 Soft film, semi-fluid, applied by brushing or swabbing to give films of medium
thickness. They are usually based on solutions of suitable corrosion inhibitors, e.g.
wool fat derivatives, in mineral oils or mixtures of minerals oils and petrolatum.

Type TP6 Oil film type consisting of lubricating oils containing soluble corrosion inhibitors,
and generally applied by dipping, spraying or circulation and generally serving as
lubricants as well as temporary protectives. There are two grades:

TP 6a oil type, general purpose protective

TP 6b oil type, engine protective

Type TP7 Strippable hot dip painting/coating consisting of ethyl cellulose and small amounts
of mineral oil together with plasticises, resins and stabilisers. It is applied by hot
dip application to form tough impermeable films which can readily be stripped
from the protected article.
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 17 of 20
Rev 0 1999
Type TP8 Strippable painting/coating, cold applied, consisting of solutions of protectives
such as vinyl copolymer resins, plasticisers and stabilisers in flammable or non-
flammable solvents. They are usually applied by spraying, brushing, or dipping to
form tough impermeable films which can readily be stripped from the protected
article.

Type TP9 Volatile corrosion inhibitors consisting of substances, the vapour from which will
inhibit corrosion of ferrous metals.

Type TP10 Contact inhibitors consisting of substances which when in contact with metallic
surfaces will inhibit corrosion.

7.0 MAINTENANCE PAINTING/COATINGS

7.1 General

Surface preparation and application of maintenance painting/coatings shall be treated as for repair
systems. Areas for maintenance may be much larger and the original coating type may be
unknown.

7.2 Coating Compatibility

7.2.1 The Owner shall ensure that the maintenance painting/coatings used are compatible with an
existing system being overcoated. Solvents and resins in the maintenance painting/coating shall
not cause any cussing, blistering, lifting or dissolving of the existing system.

7.2.2 The Owner shall carry out such tests on small sample areas, and on small flakes taken for laboratory
study as are necessary to ensure compatibility if adequate background data is not available.

7.3 Existing Coating Conditions

The condition of the existing painting/coating shall be assessed and the maintenance procedure
selected in accordance with damage to the undercoat/top-coat systems. On steel substrates, any
areas of exposed steel shall be grit blasted to SIS 05 5900 Sa 2½ and the paint edges feathered. The
maintenance painting/coatings shall be applied as appropriate:

a) Undercoat Sound, Top Coat Sound with Loss of Gloss,

Treat as per Section 7.0 GES X.01 for overpainting/coating.

b) Undercoat Sound, Top Coat Damaged

Top coat shall be completely removed by sanding or light sweep blasting.

Underpainting/coating shall be checked for satisfactory adhesion and thickness. Undercoat
shall be cleaned and overcoated as Section 7.0 GES X.01.

c) Undercoat Damage Less Than 3% of Surface Area

Local repairs shall be undertaken by spot blasting, spray or brush application of

painting/coating system in accordance with the Painting/coating Schedules. On steel
substrates any areas of exposed steel shall be grit blasted to SIS 05 5900 Sa 2½ in accordance
with GES X.01 and the paint/coatings edges feathered.
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 18 of 20
Rev 0 1999
d) Undercoat Damage More Than 3% but Less Than 20% of Surface Area

Repairs shall be undertaken by abrasive blast cleaning of affected areas and spray
application of painting/coating system in accordance with the Painting/Coating Schedules.
On steel substrates any areas of exposed steel shall be grit blasted to SIS 05 5900 Sa 2½ in
accordance with GES X.01 and the paint edges feathered.

e) Undercoat Damage More Than 20% of Surface Area

Complete structure shall be abrasive blast cleaned and re-painted/coated as new work in
accordance with the appropriate Painting/Coating Schedule.

7.4 Overcoating Existing Systems

Overcoating may be applied to increase the number of coats, renew the gloss and appearance or
change the colour. In all applications the original painting/coating should be identified and the
following procedures used.

a) Overcoating Alkyds

Remove all dirt, oil and grease by washing with detergent, rinsing with fresh water and
solvent cleaning as necessary with white spirit, methyl alcohol or an approved solvent, that
will not damage the old painting/coating. After drying, any areas that still retain a gloss
should be lightly sanded. Weathered areas need no further treatment.

A compatible overcoat shall then be applied directly to the old system as per the
appropriate Schedule.

b) Overcoating Epoxies or Polyurethanes

Remove all dirt, oil and grease as per Section 7.0 GES X.01 (Note: stronger solvents may be
used). Sweep blast or sand the entire area to be overcoated, brush or blow off loose dust
and overcoat as per the appropriate Schedule.

c) Overcoating Epoxy Mastic

Remove all dirt, oil and grease as per Section 9.2 GES X.01, and overcoat as per the
appropriate Schedule.

d) Overcoating Zinc Silicate

Aged zinc silicate should be checked for soundness and freedom from mud cracking. It
should then be thoroughly wire brushed and washed with fresh water to remove zinc
corrosion salts, before drying and overpainting/coating as per the appropriate Schedule.

7.5 Upgrading of Overcoating

The maintenance programme may require that the protective performance of a painting/coating be
upgraded. Provided that the existing coating is sound, it shall usually be accomplished by cleaning
the old coating per Section 7.0, GES X.01 and overcoating with a compatible epoxy mastic
painting/coating.
 GENERAL ENGINEERING SPECIFICATION GES X.03
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Rev 0 1999
7.6 Painting/Coating Schedules for Maintenance Works

Schedule Designated Use

MS1 Coatings for maintenance of alkyds systems.

MS2 Coatings for maintenance of solvent-based epoxy systems.

MS3 Coatings for maintenance of epoxy mastic systems.

MS4 Coatings for maintenance of zinc silicate systems.

MS5 Coatings for maintenance of water based concrete coatings.
MS6 Coatings for maintenance of recoatable polyurethane top coat systems.

MS7 Coatings for maintenance of hard gloss top coat systems

The Vendor/Contractor shall agree with the Owner the type of damage and the maintenance
procedures in accordance with Section 7.3 before commencement of the work.

Maintenance System MS1

Section 7.0
Applicable Substrate: Painting/coatings for the maintenance of alkyd systems
Surface Preparation: Requirements of GES X.01, Section 7.0 and by removing all dirt, oil and grease by
washing with detergent, rinsing with fresh water and solvent cleaning as necessary with white spirit, methyl
alcohol or approved solvent that will not damage the old painting/coating. After drying, any areas that still
retain a gloss should be lightly sanded, weathered areas need no further treatment.

First Coat: High build alkyd primer (80µm)

Second Coat: Alkyd gloss finish (40µm)

Maintenance System MS2

Applicable Substrate: Painting/coatings for the maintenance of solvent based epoxy systems.
Surface Preparation: Requirements of GES X.01, Section 7.0 and by removing all dirt, oil and grease by
washing with detergent, rinsing with fresh water and solvent cleaning as necessary with white spirit, methyl
alcohol or approved solvent that will not damage the old painting/coating.

Sweep blast or sand-paper the entire area to be overcoated, brush or blow off loose dust.

First Coat: High build polyamide cured epoxy (140µm)*

Second Coat: As first coat (50µm)

* Owner may approve thinner coat or omission of first coat.

 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 20 of 20
Rev 0 1999
Maintenance System MS3

Applicable Substrate: Painting/coatings for the maintenance of epoxy mastic systems.

Surface Preparation: Requirements of GES X.01, Section 7.0 and by removing all dirt, oil and grease by
washing with detergent, rinsing with fresh water and solvent cleaning as necessary with white spirit, methyl
alcohol or approved solvent that will not damage the old painting/coating. After drying, any areas that still
retain a gloss should be lightly sanded, weathered areas need no further treatment.

First Coat: Epoxy mastic aluminium (100µm)

Second Coat: Recoatable polyurethane (40µm)
Third Coat: As per second coat

Note:

1. If it is agreed that polyurethane colour coat is required, two coats will be necessary to cover the
colour of the epoxy mastic aluminium.

Maintenance System MS4

Applicable Substrate: Painting/coatings for the maintenance of zinc silicate systems.

Surface Preparation: Requirements of GES X.01, Section 7.0 and scrubbing sound zinc silicate with a wire
brush to remove corrosion deposits and washed with water. Final rinses shall be with fresh water.

First Coat: Zinc rich epoxy primer (50µm)

Second Coat: High build epoxy with micaceous iron oxide (MIO) pigments (150µm)
Third Coat: As second coat (150µm)

Maintenance System MS5

Applicable Substrate: Painting/coatings for the maintenance of water based concrete painting/coatings
Surface Preparation:
Sound paint surfaces: wash and scrub as necessary to remove dirt. Wash with fresh water, dry until surface
is only damp.

Damaged paint surfaces: Power clean or abrasive blast to expose clean concrete. Repair concrete with
proprietary filler as necessary. Brush and wash clean all surfaces. Dry thoroughly

Over sound paint.

First Coat: High build vinyl emulsion (50-75 µm)

Over areas of exposed concrete

First Coat: Proprietary sealer
Second Coat: High build vinyl emulsion (50-75 µm)
Third Coat: As second coat

Maintenance System MS6

Applicable Substrate: Painting/coatings for the maintenance of recoatable polyurethane top coat systems.
Surface Preparation: Requirements of GES X.01, Section 7.0 and removing all dirt, oil and grease by
washing with detergent, rinsing with fresh water and solvent cleaning as necessary with white spirit, methyl
alcohol or approved solvent. Clean recoatable polyurethane surfaces can be overcoated without sweep
blasting. However if the underlaying epoxy system is exposed it will need to be sweep blasted before
overpainting/coating.
 GENERAL ENGINEERING SPECIFICATION GES X.03
EXTERNAL PROTECTIVE COATINGS Page 21 of 20
Rev 0 1999

Overcoating System

First Coat: Recoatable polyurethane (50-70 µm)

Second Coat: As first coat

Note 1: Vendor/Contractor must carry out tests or provide certification that the recoatable polyurethane is
compatible with the old polyurethane that requires maintenance. For example if the old system is
not of the modern recoatable type it will have to be sweep blasted before painting.

Overcoating or repair of damage to undercoat

The undercoat system will be an epoxy or polyurethane and can only be overcoated with the recoatable
polyurethane after sweep blasting.

Repair of damaged undercoat

The damaged undercoat shall be blasted back to a sound surface or to bare metal as necessary and the edges
shall be feathered. All paint shall be sweep blasted, loose dust shall be brushed or blown off and the original
painting/coating thickness shall be restored as follows.

First Coat: High build epoxy (As necessary to restore original thickness)
Finish Coat: Recoatable polyurethane

Maintenance System MS7

Applicable Substrate: Painting/coatings for the maintenance of hard gloss polyurethane top coat systems.
Surface Preparation: Requirements of GES X.01, Section 7.0 and removing all dirt, oil and grease by
washing with detergent, rinsing with fresh water and solvent cleaning as necessary with white spirit, methyl
alcohol or approved solvent. Sweep blast or sand paper the entire area to be overcoated. Remove loose
paint. Brush or blow off loose dust. Sand down exposed edges to a feather edge.

Overcoating System

First Coat: Recoatable polyurethane (50-70 µm)

Second Coat: As first coat

Note 1: Vendor/Contractor must carry out tests or provide certification that the recoatable polyurethane is
compatible with the old polyurethane that requires maintenance.

Overcoating or repair of damage to undercoat

The undercoat system will be an epoxy or polyurethane and can only be overcoated with the recoatable
polyurethane after sweep blasting.

Repair of damaged undercoat

The damaged undercoat shall be blasted back to a sound surface or to bare metal as necessary and the edges
shall be feathered. All paint shall be sweep blasted, loose dust shall be brushed or blown off and the original
painting/coating thickness shall be restored as follows.

First Coat: High build epoxy (As necessary to restore original thickness)
Finish Coat: Recoatable polyurethane
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