Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID : SP-1132

June 1999 Filing key : xxxx

General Specification

for

Plant Design Reference Manual

Keywords:

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any
part of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
General Specification for Plant Design Reference Manual Version 2.0

Authorised For Issue 30/06/1999

Signed :............................................................
G. C. Henley, OTE
CFDH, Project Engineering.

The following is a brief summary of the 2 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.

Version No. Date Author Scope / Remarks

Version 2.0 Jun, 1999 Ohi Aikhoje, OTE/4 Renamed and revised to align with CP-117,
Project Engineering Code of Practice.
Version 1.0 Mar, 1986 E. Blomsma, ETH/1 Initial issue - Preparation of Plant Design
Reference Manual.

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Version 2.0 General Specification for Plant Design Reference Manual

Contents

1. Introduction...........................................................................................................................1
1.1 Purpose..............................................................................................................................1
1.2 Changes to the Specification............................................................................................1

2. Scope.......................................................................................................................................2
2.1 Definitions.........................................................................................................................2
2.2 Process Definition.............................................................................................................3
2.3 Deliverables.......................................................................................................................3
2.4 Related Business Control Documents..............................................................................4

3 Requirements for Preparation............................................................................................5

3.1 Paper Copy........................................................................................................................5
3.2 Electronic Version.............................................................................................................5

4. Contents Overview................................................................................................................7
4.1 Typical ‘Table of Contents’..............................................................................................7
4.2 Detailed Contents..............................................................................................................8

5. Updating of Manuals..........................................................................................................11
5.1 Paper Copies....................................................................................................................11
5.2 Electronic Version...........................................................................................................11

6. Distribution..........................................................................................................................12

APPENDIX 1 - Examples of Binder Front and Spine........................................................13

APPENDIX 2 : User Feedback Page......................................................................................16

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General Specification for Plant Design Reference Manual Version 2.0

1. Introduction
1.1 Purpose

This document covers the requirements for content, presentation and updating of
Plant Design Manuals. It also provides the basis for the electronic version
accessible via EDMS.

1.2 Changes to the Specification

Responsibility for the technical content of this document rests with the Custodian
who is the Corporate Functional Discipline Head (CFDH) for Project Engineering
UEJ. Only the Custodian can give approval for changes. Any user of this document
who encounters an inaccuracy or ambiguity is requested to notify the custodian by
completing the user feedback form at the end of this document.

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Version 2.0 General Specification for Plant Design Reference Manual

2. Scope
The objective of the Plant Design Reference Manual is to provide basic design
information and comprehensive references to other technical documentation for use
by Technical Safety Audit/Hazop teams and engineers involved in plant
extension/modification or in design integrity/performance evaluation.

Emphasis is on the preparation of the document as a reference manual, and

comprehensive calculation details or information contained in other project
generated documentation, (listed overleaf), should not be included. The Plant
Design Reference Manual should principally be a compilation of documents
generated during the plant design, and there should only be a minimal amount of
specially prepared material.

With the introduction of the Plant Design Manual, design philosophy need not be
included in the Operating Manuals.

A Plant Design Reference Manual shall be prepared for every new facility and
major plant extension or modification

2.1 Definitions

for the purpose of this document the following definitions shall hold.

Shall - the word ‘shall’ is to be understood as mandatory.

Should - the word ‘should’ is to be understood as strongly recommended.

May - the word ‘may’ is to be understood as indicating a possible

course of action.

The Company - Petroleum Development Oman LLC of Muscat, Sultanate of Oman.

User - the specialist engineer, or consultant who applies this standard

in the execution of a project.

The Consultant - the party to the Contract with the Company who is responsible for
providing the design, engineering, and other related consultancy
services under the Contract.

Manufacturer/ -the party responsible for the manufacture or supply of equipment

Supplier and services to perform the duties specified by the Consultant
or Company.

Vendor -the term ‘Vendor’ is considered to be synonymous with the term

Manufacturer/Supplier.

Abbreviations

PEFS - Process and Engineering Flow Scheme

PFS - Process Flow Scheme

UFS - Utility Flow Scheme

UEFS - Utility and Engineering Flow Scheme

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General Specification for Plant Design Reference Manual Version 2.0

2.2 Process Definition

Design is mapped in the Shell EPBM v3 via the A-12 process, which is
Design/Construct/Modify/Abandon facilities. The sub processes covering design are
the A-12.01 process Prepare Conceptual Design and the A-12.02 process Prepare
Detailed Design.

Conceptual Design including Front-End Design is triggered from the Asset

Management process by a development requiring new or modified facilities or by
the need to improve an existing asset's performance or integrity. The main purpose
of this development phase is to evolve the functional requirements for a facility into
a functional specification, which provides the level of definition required to generate
a budget estimate for the facility.

Detailed Design follows completion of Conceptual/Front-End Design. The main

objective of this phase is to produce specifications, drawings, construction work
packages, commissioning plans, materials take-off and spares list such that the
facility may be built, commissioned and started up. SP-1134 (ERD-10-04), provides
the General Specification for Detailed Design and Engineering of Oil and Gas
Facilities.

2.3 Deliverables

The deliverables from the design process is fully detailed in CP-117 Project
Engineering Code of Practice.

Normally, for a single facility, the information and documentation required would not
exceed that which could be contained in two 50 mm binders.

It should be noted that the PDO Plant Design Reference Manual is essentially
different from the ‘Design Book’ defined in DEP 01.00.02.11-Gen, which is basically
a project design file specifically developed for SIPM – Manufacturing working
processes.

The Plant Design Reference Manual which is one of a number of technical documents
produced for a project during the design phase should contain references to the following
(see also 4.2):

Description References

 Asset Development Plan (ADP) BDM/032/96

 Design Integrity Register PR-1232
 IPF Classification Reports DEP 32.80.10.10-Gen
 Material Selection Philosophy and Corrosion ERD-49-01
Control Procedures
ERD-49-02
 HSE Assessment including HAZID and HAZOP HSE/96/01
Reports.
EP 95-0230
EP 95-0240
EP 95-0312
EP 95-0313
EP 95-0352

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Version 2.0 General Specification for Plant Design Reference Manual

2.4 Related Business Control Documents

The following are related Business Control documents;.

Code of Practice CP-117 Project Engineering Code of Practice

Specifications SP-1131 Hand over and As-built Documentation.

(ERD-00-05)

SP-1134 General Specification for Detailed Design

and Engineering of Oil and Gas Facilities.
(ERD-10-04)

Procedures PR-1239 Project Drawing Procedures.

(ERD-00-14)

Guidelines ERD-00-10 The Proposal, Production, Issue and

Maintenance of Engineering Reference
Documents.

EP-96-3000 Project Management Guidelines

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General Specification for Plant Design Reference Manual Version 2.0

3 Requirements for Preparation

3.1 Paper Copy

- Presentation of Plant Design Manuals, i.e. presentation of layout of text and

illustrations, numbering, presentation of data and binding, shall be in
accordance with ERD-00-10, ‘The Proposal, Production, Issue and
Maintenance of Engineering Reference Documents’, with the following
amendments:-

- The front and spine of each binder shall have a white background with
lettering printed in black. The minimum letter height shall be 5 mm on the
front and 3 mm on the spine. Refer to Appendix 1 for example.

- If spine width permits, the spine title shall be printed across the spine,
otherwise it shall be printed along the spine in such a way as to be readable
when the manual is lying flat with the front cover uppermost.

- The maximum depth of paper in any binder shall be 40 mm. The maximum
binder size shall be 50 mm measured as the inner dimension of retaining
rings.

- The rings of the binder shall be attached to the back of the binder, not the
spine.

- The Consultant’s name or logo shall not appear on front or spine of the
binders.

- For small projects, all the A4 documents and A3 drawings and documents
may comfortably fit into one A4 binder.

- For larger projects, A3 drawings and documents shall be in A3 binders.

The front and spine of each binder shall clearly state:-

PLANT DESIGN MANUAL

‘Field name – plant (extension) name

‘Volume x of y’ (if more than one binder)

‘Month Year’

PETROLEUM DEVELOPMENT OMAN LLC

3.2 Electronic Version

As emphasis is on the preparation of the Plant Design Reference Manual as a

compilation of key documents/drawings generated during the design phase of a
project, hyperlinks to other project drawings/documents should be created in the
electronic version.

Each section of the Plant Design Reference Manual (detailed in 4.2) should have an
introduction and link to the relevant drawing/document stored in EDMS.

With the introduction of the electronic version, it is recommended that a maximum of

three paper copies be produced for a project, distributed in line with Section 6 of this
document.

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Version 2.0 General Specification for Plant Design Reference Manual

4. Contents Overview
Typically the contents of the Plant Design Reference Manual shall be grouped under
the headings listed in 4.1 below.

4.1 Typical ‘Table of Contents’

Title Page
Preface
List of Contents

1.0 INTRODUCTION AND SUMMARY

2.0 DEFINITIONS AND ABBREVIATIONS

3.0 PROJECTS SCOPE AND DESIGN CRITERIA

4.0 LIST OF CODES AND STANDARDS

5.0 REFERENCES

6.0 DESIGN BACKGROUND

6.1 STANDARDISATION
6.2 PROCESS DESIGN
6.3 PROCESS CONTROL
6.4 PLANT LAYOUT
6.5 UTILITIES
6.6 INTERFACES WITH OTHER FACILITIES
6.7 CIVIL AND STRUCTURAL
6.8 MECHANICAL EQUIPMENT (STATIC AND ROTATING)
6.9 PIPING
6.10 ELECTRICAL
6.11 INSTRUMENTATION
6.12 SHUTDOWN PHILOSOPHY
6.13 FIRE AND GAS PROTECTION
6.14 CORROSION MANAGEMENT

7.0 HSE ASSESSMENT

8.0 LIST OF MAIN EQUIPMENT

9.0LIST OF REQUISITIONS

10.0 LIST OF DRAWINGS

11.0 SELECTED ENGINEERING CONSULTANTS AND VENDOR

12.0 DATA SHEETS

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General Specification for Plant Design Reference Manual Version 2.0

4.2 Detailed Contents

Title Page

The title page shall contain following information.

PLANT DESIGN MANUAL

‘Field Name – Plant (extension) Name
‘Volume x of y’ (if more than one volume)
‘Month, year’

Prepared by
‘Consultant Name’
‘Project Number B.I. XX. XXX’

Preface

The preface shall state the objective of the manual.

List of Contents

1.0 INTRODUCTION AND SUMMARY

This section shall contain a brief description of the project/plant, its objectives and
the area and location.

2.0 DEFINITIONS AND ABBREVIATIONS

This section shall describe definition and abbreviations of terms used in the manual.
Internationally recognisable abbreviations, e.g. API, ASME, BS, etc, need not be
included.

3.0 PROJECT SCOPE AND DESIGN CRITERIA

This section shall specify the criteria on which the design is based including;

- plant throughput
- number of wells.
- type of facility

This section may be an update of the document of the same name issued to the
Consultant as part of the Project Specification.

4.0 LIST OF CODES AND STANDARDS

This section shall contain a list of standards, specifications and codes used in the
project with revision number/date.

5.0 REFERENCES

This section shall contain references to studies, reports, manuals, design

documentation and contracts applicable to or prepared for the project.

6.0 DESIGN BACKGROUND

For each of the subsections listed under DESIGN BACKGROUND, the criteria and
reasons for the selection of (sometimes referred to as DESIGN PHILOSOPHY), a
particular system, equipment, structure or process against those alternatives
considered, shall be summarised for each system, equipment, structure or process.

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Version 2.0 General Specification for Plant Design Reference Manual

The Consultant shall highlight the considerations given to particular areas of design
such as optimisation, allowance for future extension, specific design safety features,
materials selection, the use of uncommon standards, the application of new
technology, etc. Specific data and descriptions already covered in the ‘Plant Operating
Manual’ or on Engineering Drawings shall not be included unless required to describe
the design background.

The content of studies shall not repeated but adequate references shall be made in the
section.

For each main item the design basis shall be summarised including details such as:-

- Method of calculation or code used including specific computer programme used.

- Design restrictions and assumptions made with respect to design parameters

(loading, pressure, pressure drops, fouling factor, etc.). Typical information
that might be included is, ‘All vessels are designed for full, shut-in well head
pressure’ or ‘Maximum design gas velocity in process pipe work is xx m/s’.

- Application of special materials, e.g.,extent of sour service materials, use of low

temperature/stainless steels or coatings, etc.

- Input data/loading conditions.

- Safety factors allowed.

- Provisions made for future additional loads, extensions increased capacity, etc.

- Essential outcome of results of calculations, e.g., the ground concentration of SO 2

determined from dispersion calculations.

The design details shall be complementary to information provided on the included data
sheets. Detailed numerical calculations or descriptions shall not be included.

A list of subheadings required in this section is shown from 6.1 to 6.14 inclusive under
section 4.1 of this document.

7.0 HSE ASSESSMENT

This section shall describe the HSE considerations in design including the tools used.
Hazards identified and the management of the hazards shall be included.
Environmental Impact Assessment (EIA) carried out should be referred to in this
section as well as Environmental Impact Statement (EIS).

8.0 LIST OF MAIN EQUIPMENT

This shall be a complete list with all non-MESC coded equipment.

9.0LIST OF REQUISITIONS

This shall be a complete listing of equipment and materials purchased for the project,
documented with title and indent number.

10.0 LIST OF DRAWINGS

This shall be a complete list of engineering drawings in sequence of engineering

section followed by Vendor drawings in sequence of indent number. +

11.0 SELECTED ENGINEERING CONSULTANT AND VENDOR DRAWINGS/

DOCUMENTATION.

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General Specification for Plant Design Reference Manual Version 2.0

This shall include a selection only of copies of drawings which may be useful as
reference documentation. A1 originals shall be reduced to A3. Other size originals shall
be reduced to A4.

PFS.
UFS.
PEFS.
UEFS.
Area Layout.
Plot Plans.
Single-Line Diagrams.
Shutdown Matrix Diagrams
Piping Specifications.
Main Equipment Cross-sectional Drawings and PEFS's.

12.0 DATA SHEETS

Main Equipment Data Sheets and Data Requisition Sheets.

Electrical utility Data Sheets.
Instrumentation Data Sheets.
Piping Data Sheet (Line Lists).
Pressure Relief Master Schedule DS-38-01.
Level Gauge Data Sheets.

+ If a control report was maintained for the project, a reproduction of the final
revision is acceptable and the list need not be retyped.

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5. Updating of Manuals
5.1 Paper Copies

When major plant extensions or modifications are made, substantially invalidating the
existing manual, a new manual shall be prepared.

For minor changes the manual shall be updated by the preparation of addenda sheets.
The addenda shall contain cross-references to the numbered sections of the manual
initially prepared for the facility, indicating the changes made. Each addenda sheet
shall be numbered sequentially.

A front sheet shall be prepared for each set of addenda sheets, containing the following
information:

PLANT DESIGN MANUAL

ADDENDUM A (alpha-sequential letters shall be used

for each issue following a minor plant change)

Field Name – Plant Name

Description of Modification

Month and Year

Number of pages in the issue.

PDO will advise the Consultant at the start of a project whether addenda sheets or a
new updated manual is required.

When a number of small plant modifications occur on a particular facility over a period
of time, resulting in multiple addenda, PDO Engineers may request the initiation of an
exercise to integrate all addenda into a new manual.

5.2 Electronic Version

As above, once modifications to a plant are made, and linked drawings/documents are
revised, the manual should be updated automatically and revision version, date of
revision stored to file.

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General Specification for Plant Design Reference Manual Version 2.0

6. Distribution
A total of three copies of the Plant Design Reference Manual or updates shall be made
and distributed to:-

1. Engineering Library (1x)

2. Area Operations Co-ordinator (1x)
3. Engineering Team Leader (1x)

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Version 2.0 General Specification for Plant Design Reference Manual

APPENDIX 1 - Examples of Binder Front and Spine

PLANT
PLANT DESIGN
DESIGN REFERENCE MANUAL
REFERENCE
MANUAL

XXXX PRODUCTION
STATION

XXXX

PRODUCTION
VOLUME 1 OF 2
STATION

Month/Year

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General Specification for Plant Design Reference Manual Version 2.0

VOLUME 1 OF 2

Month/Year

PETROLEUM PETROLEUM DEVELOPMENT OMAN

LLC.
DEVELOPMENT

OMAN LLC

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Version 2.0 General Specification for Plant Design Reference Manual

PLANT DESIGN
REFERENCE
PLANT DESIGN
MANUAL
REFERENCE MANUAL
XXX
PRODUCTION
STATION

Volume 1 of 2
XXXX PRODUCTION STATION
Month/Year VOLUME 1 OF 2

PETROLEUM
DEVELOPMENT Month/Year
OMAN LLC

PETROLEUM DEVELOPMENT OMAN LLC.

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General Specification for Plant Design Reference Manual Version 2.0

APPENDIX 2 : User Feedback Page

From :

To : UEJ

Any user who identifies an inaccuracy, error or ambiguity is requested to notify the custodian so that
appropriate action can be taken. The user is requested to return this page fully completed, indicating
precisely the amendment(s) recommended.

USER DATE REMARKS

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