NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.61

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL GUIDELINES

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 Contractural 4

3.0 DESIGN 4

3.1 Codes and Standards 4

4.0 INDEX 4

5.0 CONTENT 5

5.1 General 5
5.2 Manual Contents 5
5.3 General Requirements 8
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for compiling Installation, Operation and Maintenance
Manuals for plant and equipment, for refineries, onshore oil and gas installations and processing facilities.

1.1.2 The Vendor/Contractor shall produce a comprehensive Manual that gives specific details of all aspects of
the plant and equipment supplied. A compendium of manufacturer's data for a range of like products is not
acceptable.

1.1.3 The Manual shall be a complete reference document, containing all drawings, descriptions and procedures.

1.1.4 The Vendor/Contractor may include manufacturers' standard literature in the Manual but such literature
shall be modified to be specific to the plant and equipment supplied, e.g. actual model number, tag number
and type of plant and equipment must be clearly indicated, together with any special modifications.

1.1.5 The Manual shall be presented in A4 format, securely bound in heavy duty, 4 ring binders and provided in
the number of copies and format as detailed in the Purchase Order/Contract, or as agreed with the Owner.

1.1.6 Reference shall be made in the Manual to the Owners' published Safety Procedures and preferred working
practices, outlined in NOC General Engineering Specifications.

1.2 Other NOC Specifications

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

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 Contruction Sites

GES C.05 Mechanical Equipment Installation Practices

GES C.06 Electrical Installation Practices

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.57 Chemical Cleaning of New Piping

GES C.58 Chemical Cleaning of Steam Equipment and Piping Systems

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

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

2.0 DEFINITIONS

2.1 Technical
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Technical Terms used in the Manual shall be those in common usage for the equipment concerned. The
Vendor/Contractor shall define unusual terms within the Manual.

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

The relevant Codes and Standards to which the plant and equipment have been designed and constructed,
shall be clearly stated in the Manual.

4.0 INDEX

4.1 The Vendor/Contractor shall submit for Owner approval, an index for the Manual. The index shall be
arranged to enable the relevant documents on any individual item to be easily located, within a plant or
equipment package.

4.2 The index shall include individual sections on all the ancillary items that make up the plant or equipment
package. Each section shall conform to the following general format:-

(a) Plant Name;

(b) Equipment Name;
(c) Description;
(d) Master Document List;
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(e) Storage and Unpacking Instructions;
(f) Installation Procedures - Mechanical;
(g) Installation Procedures - Electrical/Instruments;
(h) Commissioning and Start-Up Procedures;
(i) Operating Procedures;
(j) Shutdown Procedures;
(k) Dismantling and Reassembly Instructions;
(l) Maintenance Procedures;
(m) Trouble Shooting;
(n) Lubrication and Utilities Schedule;
(o) Instrumentation Control and PLCs;
(p) Normal Operating Values;
(q) Special Tools;
(r) Drawings and Documents;
(s) Parts Lists;
(t) Spare Parts;
(u) Manufacturer's Literature.

5.0 CONTENT

5.1 General

5.1.1 The complete Manual will be prefaced by a title page that shall give details of the Owner, title of the
project, operating location, Purchase Order/Contract Number, equipment title and tag numbers.

5.1.2 The title page and index shall be followed by an Introduction which shall present the range of plant and
equipment covered in the manual and the process it performs. A site map, schematic diagram or full plant
layout shall be included for reference.

5.1.3 After the Introduction each manual shall include the sections as listed in 4.2 above and as further defined in
5.2 below.

5.2 Manual Contents

The manual shall include:

5.2.1 Description

A description of the equipment. For packages, this shall include the specification, as built Data Sheets, an
explanation of the process and the operation and control philosophy.

5.2.2 Master Document List

This shall include a complete list of final certified drawings, documents, PFDs, P&IDs, and final
performance test curves as approved by the Owner.

5.2.3 Storage and Unpacking Instructions

This shall include details of preservation requirements for storage at site, whilst awaiting commissioning,
and preservation materials used internally. Full details for off-loading shall be stated.
The storage instructions shall take into account the temperature range and humidity expected on site and
shall make recommendations on the requirements for:-

- periodic rotation of equipment shafts;

- protection/treatment of exposed shafts, keyways, couplings, bearings;
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- replacement of rust preventives. The quantity, timing and weight of dessicants and volume of rust
preventive oil.

5.2.4 Installation Procedures (Mechanical)

The Vendor/Contractor shall give full installation instructions for the plant and equipment including
preparation of the foundation surface, lifting, positioning, levelling, aligning, shimming and grouting.

Step by step procedures with hot and cold alignment and clearance data, including procedures for field
painting, pipework assembly and cleaning, site welding and pressure testing, shall be provided.

The Vendor/Contractor shall state any special instructions regarding the preparation or roughening of the
foundation top prior to lifting the equipment into position on the foundation. The type and quantity of
grout, holding down bolts or welding required shall also be stated.

Reference shall be made to GES C.05.

5.2.5 Installation Procedures (Electrical/Instruments)

Installation procedures for all electrical equipment including intrinsically safe instruments shall be given to
enable Approval Authority certification requirements to be met.

Reference shall be made to GES C.06 and GES C.55.

5.2.6 Commissioning Start-Up Procedures

This shall include step by step procedures for precommissioning and commissioning checks with a
recommended starting and running-in procedure.

Reference shall be made to GES C.54, GES C.56, and GES C.60.

5.2.7 Operating Procedures

This shall include normal operating procedure, special safety precautions, analytical checks, data to be
logged. The Vendor/Contractor shall give the limits within which the operating parameters should be
maintained.

5.2.8 Shutdown Procedures

This shall include both normal and emergency shutdown procedures.

5.2.9 Dismantling and Reassembly Instructions

This shall include step by step procedures for dismantling and re-assembly. All plant and equipment fits
and clearances shall be stated together with required torques on all bolting, etc.

5.2.10 Maintenance Procedures

(i) Routine Operation Maintenance

The Vendor/Contractor shall list the activities that should be carried out on a frequent basis, daily, weekly
or other, including checking and minor adjustments which it is possible to carry out while the equipment is
running. This will also include the conditions and readings that are to be recorded and these shall be
presented in the form of a simple check sheet.

(ii) Intermediate Maintenance

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Intermediate maintenance is that which can be effected within a brief shutdown and does not require
substantial disassembly of the equipment. The time interval for this type of maintenance will depend on the
operating conditions. The Vendor/Contractor shall list the maintenance activities and the
minimum/maximum operating hours when the activities shall be carried out.

(iii) Major Maintenance/Overhaul

The Vendor/Contractor shall state the operating hours or other interval or condition when major
disassembly will be required. The Vendor/Contractor shall identify which major components need to be
inspected, if not replaced. The Vendor/Contractor shall also identify which components the Owner should
keep as spares, prior to a major overhaul.

5.2.11 Trouble Shooting

The Vendor/Contractor shall provide "trouble shooting" information on the equipment, instrumentation and
controls. This shall take the form of a list of observed defects in equipment performance, e.g. high
temperature, noise, or vibration etc., together with a list of likely causes and their remedies. Logic
Diagrams shall also be included to assist in fault finding and diagnosis.

5.2.12 Lubrication and Utilities Schedule

This shall include a lubrication schedule with type of lubricant, first fill quantities and change frequency.
All air, water and power utilities consumption shall also be stated.

5.2.13 Instrumentation Control and PLC's

A separate section in the manual devoted to the Instrumentation and Controls shall have a complete and
detailed description of the control operation with specific component operating parameters. Where there
are separate sections for the various items within a package, this section can be limited to those
instruments, panels and controls directly associated to that section with an overview and operational
relationships detailed in the Introduction (see 5.1.2). For programmable logic controllers supplied by the
Vendor/Contractor, a copy of the programme and re-programming procedure is required.

5.2.14 Normal Operating Values

This shall include normal operating values for all gauges, instruments, and any other adjustable
components, e.g. alarm and trip settings, ESD valve closure times, maximum vibration limits, relief valve
settings, timer and electrical potential relay settings.

5.2.15 Special Tools

A list of special tools is required.

5.2.16 Drawings and Documents

This shall include all the drawings listed in the Master Document List plus those additional documents not
listed above and not included in the Manufacturing Data Book.

5.2.17 Parts List

This shall include cross-sectional, or exploded view isometric drawings detailing each individual
component in the equipment. Each component shall be identified by an illustration number, a unique part
number and part description. This latter list of parts together with the equipment model, type and serial
number shall provide a unique description of each component.

5.2.18 Spare Parts

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The following shall be listed:-

i) commissioning spares;
ii) consumable spares for 2 years' operation;
iii) insurance spares.

5.2.19 Manufacturer's Literature

Manufacturer's literature annotated to indicate actual equipment shall be supplied.

5.3 General Requirements

5.3.1 Parts List

The parts lists for each separate item of equipment shall bear the manufacturer's name, address and contact
telephone, telex and facsimile numbers, to allow rapid direct ordering of any components required. The
parts list should also bear the equipment type, model no. and serial number of the equipment.

5.3.2 Drawings

Drawings shall be A4 or A3 size, except where definition and/or legibility is affected. Full size drawings
shall be provided, folded in wallets.

Drawings and all technical data may be provided on computer disc or other electronic system, by prior
agreement with the Owner, or as detailed in the Purchase Order/Contract.

5.3.3 Supporting Documentation

All associated relevant information and specifications shall be scheduled in a concise bibliography which
shall include reference to suppliers, publishers or other sources.

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