NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES P.04

PLANT AND PIPING MODEL

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES P.04
PLANT AND PIPING MODEL 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 Function 5
3.3 Presentation 5
3.4 Colour Coding 5
3.5 Identification and Tagging 6
3.6 Accessories 7

4.0 MATERIALS AND CONSTRUCTION 7

4.1 Model Base Boards 7

4.2 Piping 7
4.3 Buildings 7
4.4 Equipment Plinths 8
4.5 Steel Structures 8
4.6 Concrete Structures 8
4.7 Vessels, Drums and Exchangers 8
4.8 Electrical 8
4.9 Instrumentation 9

5.0 MODEL WORKSHOP 9

5.1 General 9
5.2 Safety and Operation 9
5.3 Location 10

6.0 PROGRESS, REVIEWS AND APPROVALS 10

7.0 PHOTOGRAPHY 10

8.0 PACKAGING AND SHIPMENT 11

9.0 SITE ASSEMBLY 11

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PLANT AND PIPING MODEL Page 3 of 11
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the general requirements for design, assembly, review and approval of plant and
piping models.

1.1.2 This specification applies to models for Refineries, Onshore Oil and Gas Installations, and Processing
Facilities including items purchased either directly or as a part of a package.

1.1.3 The plant and piping model shall provide a three dimensional presentation of a process or utility unit or
groups of units for use by the Vendor/Contractor and the Owner during the design engineering and
construction phases and subsequently for Operators training during commissioning.

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 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 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 P.01 Piping Material Specification

GES P.02 Plant Piping Systems

GES X.02 Colour Coding of Equipment and Piping

2.0 DEFINITIONS

2.1 Technical

Piping Design General Arrangements

These are fully dimensioned and accurate working drawings showing the piping design layout within a
plant area.

Piping Isometrics

A detail sketch of an individual process or utility line, drawn as an isometric three dimensional single line
diagram, not to scale, at an angle of 30 degrees to the horizontal plane. This drawing shows all of the
essential components of a line, including a bill of material.
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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 Plant and Piping Model.

Vendor

The company supplying the equipment and material.

Contractor (where Applicable)

The main Contractor for a defined piece of work.

Sub-Contractor (where Applicable)

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

American National Standards Institute (ANSI)

ANSI B16.10 Face-to-Face and End-to-End Dimensions of Ferrous Valves

ANSI B31.3 Chemical Plant and Petroleum Refinery Piping

ANSI Z356.4 Modelling Materials

3.1.2 Deutsches Institute Fϋr Normung

Din 2408 - (pt 2. supp1) - Piping Systems

- Piping Models : Examples

3.1.3 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.
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3.2 Function

3.2.1 The plant and piping model shall be effectively employed by the Vendor's/Contractor's Design Department
to develop an optimum plant and piping layout, which shall be easy to operate and maintain. The model
shall allow for a comprehensive study by the design personnel of all equipment and piping to ensure that all
requirements have been met.

3.2.2 Upon completion of the model, the piping general arrangement drawings shall be finalised, using the model
for reference.

3.2.3 When final design is completed, and approved by the Owner, the model shall be used as reference during
the construction phase of the contract.

3.2.4 The model shall be fully updated to include any construction or commissioning modifications made. The
model shall then be handed over to the Owner to be used for operator training and operational reference.

3.2.5 The model is particularly useful for presentation of a process plant to non-technical personnel and for
public demonstration.

3.3 Presentation

3.3.1 Scale

The Plant and Piping model shall be built to a scale of 1:331/3

Any variation on this scale shall be subject to approval by the Owner.

3.3.2 Accuracy

Overall dimensions of 24" (600 mm) or more shall be within an accuracy of ¼" (6 mm).

Individual dimensions shall be within an accuracy of 1/8" (3 mm).

3.3.3 Model Base Boards

a) The Plot Plan area drawing shall be divided into baseboard sections and numbered accordingly.

b) Base boards shall be sized so that they are easy to handle, and all parts of the baseboard can easily
be worked on.

c) Base boards shall be divided into specific process area where possible, i.e. furnace area,
demethanizer area etc. Baseboard division lines shall avoid equipment or structures.

d) Consideration shall be given to the eventual dispatch of the baseboards, which should be sized to
pass through doorways or other exits, or into elevators on the premises where the model is being
built.

3.4 Colour Coding

3.4.1 Plant and Piping

Plant and piping shall be colour coded in accordance with GES X.02.
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Valves and other components such as strainers shall be the same colour as the parent pipe.

Vendor/Contractor supplied piping for equipment shall be painted Mid-Grey.

3.4.2 Instruments

Control Valves Pink

Relief Valves Pink
Level Displacers Pink
Level Alarms Pink

3.4.3 Other Items

Pipes & In-Line Instruments Grey

Concrete Plinths and Supports Light Grey
Concrete Structures Light Grey
Steelwork Dark Grey
Buildings Beige
Vessels and Equipment Mid-Grey
Utility Hose Stations White
(Outline)
Fire Hydrants Dark Red
Fire Hose Reels Dark Red
Roads, Accessways, Escape Routes Black Tape 1/16" (1.5 mm) wide
Valve Boxes, Manholes, Cable Black Tape cut to required size.
and Pipe Trenches

3.5 Identification and Tagging

3.5.1 Piping

Each line shall be tagged with the appropriate line number in accordance with the line designation table.
The line tags shall be white paper laminated arrow-shaped labels.

3.5.2 Instruments

All instruments shall be tagged with the appropriate number on a paper lamination button.

3.5.3 Steel Structures (Including Pipe Racks)

Structure and piperack columns shall be tagged with the appropriate column number.

3.5.4 Vessels and Equipment

All items shall be tagged with a white label showing the appropriate equipment number. All nozzles shall
be tagged with the correct nozzle number. Platforms shall be tagged with the correct elevation.

3.5.5 Base Boards

Each baseboard shall have a nameplate made from 1/8" (3 mm) thick Perspex, located at one corner of the
base board. The name plate shall give the title of the contract and process area, the contract number, the
Base Board number and Plant north arrow.
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Rev 0 1999

3.5.6 Miscellaneous

All miscellaneous items such as local instrument panels, power and lighting panels, transformers, shall be
tagged with the appropriate item number.

3.5.7 Buildings

Buildings shall be identified with the building description and number.

3.6 Accessories

3.6.1 Models

Scaled models of people and vehicles to help visualisation of plant dimensions.

4.0 MATERIALS AND CONSTRUCTION

4.1 Model Base Boards

Base boards shall be made of ¾" (20 mm) plywood or particle board, with a wood underframe. The surface
shall have a white matt plastic coating. Base boards shall be supported on legs that can be easily removed.
Base boards shall have locating dowels and matching holes so that they may be accurately butted together.

4.2 Piping

4.2.1 Pipe and fittings shall be represented by scale size pre-moulded polypropylene tubing and fittings. Valves
and Control Valves shall be represented in a similar manner.

4.2.2 When model valves representing valves in high pressure service are not available, they shall not be
substituted by valves representing a lower pressure, but shall be made in block form from soft wood.

4.2.3 Insulation section in white styrofoam shall be shown on lines with insulation thickness 4" (100 mm) and
above.

4.2.4 Valve handwheels, actuators and gear operators shall be accurately shown to scale.

4.2.5 Pipe shoes shall not be shown on the model.

4.2.6 Pipe supports such as base supports and dummy legs shall be shown only when convenient for supporting
the model pipe, i.e. at control valve sets.

4.2.7 Major pipe supports such as T-posts shall be shown on the model.

4.2.8 Process vents and drains shall be indicated on the pipe by using paper laminated buttons, marked "V" or
"D". Test Vents and Drains shall not be shown.

4.3 Buildings

If a building contains operating equipment (i.e. compressors, pumps, vessels, etc.) it shall be fabricated in
cut-away form. Buildings that do not contain operating equipment (i.e. control rooms. MCC rooms,
analyser houses etc.) shall be fabricated in block form with doors and windows indicated.
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4.4 Equipment Plinths

Plinths shall be fabricated from wood block or 3-ply, and accurately made to indicate the correct size and
plinth height.

4.5 Steel Structures

4.5.1 Steel structures shall be made from pre-moulded sections to the correct scale size.

4.5.2 All steel cross bracing shall be shown.

4.6 Concrete Structures

Concrete structures shall be made from wood and painted light grey.

4.7 Vessels, Drums and Exchangers

4.7.1 Cylindrical Vessels, Drums and Exchangers shall be made to scale from plastic pipe or from wood turned
to the correct diameter.

4.7.2 Vessel heads shall be represented by the equivalent size of pipe caps, or turned on a lathe in hard wood.

4.7.3 Tower skirts that are flared shall be turned on a lathe in hardwood.

4.7.4 Manholes, handholes, nozzles and other attachments shall be made from pre-moulded items where possible.
Manhole and exchanger cover davits and hinges shall be shown in the correct orientation.

4.7.5 Platforms at vessels and structures shall be made from cross-hatched plexiglass.

4.7.6 Stairways and ladders shall be cut from pre-moulded section.

4.7.7 Platform bracing and supports shall be shown accurately to scale.

4.7.8 Level instruments and instrument standpipes shall be shown to scale.

4.7.9 Gauge glasses shall be represented by 1/8" (3 mm) square plexiglass.

4.8 Electrical

4.8.1 The installation of electrical equipment on the model shall be in block form representing the extreme
outline of the equipment. Overhead cable trays or conduit racks shall be in block form. Tray shall be
fabricated to scale from styrofoam or plastic, showing width, depth and routing of major runs.

4.8.2 Additionally, the following electrical equipment shall be installed on the model:-

Transformers
Switch racks
Lighting and power panels
Surface outline of underground pull boxes or manholes
Above ground pull boxes or manholes
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4.9 Instrumentation

4.9.1 In-line instruments such as control valves, relief valves, orifice/carrier plates etc. shall be installed as
indicated on the piping and instrument diagram (P & ID) and shall be coloured grey.

4.9.2 Thermal relief valves shall not be installed or tagged.

4.9.3 Local instrument transmitters shall be installed.

4.9.4 Major instrument racks shall be fabricated to scale from styrofoam or plastic, showing width, depth and
routing.

4.9.5 Additionally, the following instruments and associated equipment shall be shown:-

- Local instrument panels (free standing or part of a packaged unit),

- Junction boxes,

- Instrument and analyser houses,

- Individual conduit runs, air supply connections on the instrument air header, instrument piping and
instrument valves shall not be shown.

5.0 MODEL WORKSHOP

5.1 General

5.1.1 A workshop equipped with adequate tools and machinery for building the plant model shall be supplied by
the Vendor/Contractor on or near the premises where the model is being built.

5.1.2 It is the responsibility of the Vendor/Contractor to ensure that the workshop facilities fully meet the safety
and operating requirements of the relevant national and local authorities.

5.2 Safety and Operation

The following minimum requirements shall apply:

(a) The Vendor/Contractor shall provide protective clothing and equipment, such as eye protectors
and face masks.

(b) The workshop layout shall provide a minimum of 3 ft 3" (1 m) in front of a work bench, and a
minimum of 5 ft (1.5 metres), between adjacent work benches.

(c) There shall be adequate lighting (1000 Lux min) and ventilation in the workshop area.

(d) Workshop machinery shall have protective guards around exposed moving parts to prevent injury
to workshop personnel.

(e) Flooring shall be the non-slip type.

(f) A comprehensive first aid kit shall be supplied.

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(g) A separate well ventilated area, shall be allocated for paint spraying or solvent use. Workshop
personnel shall be advised of the hazards of using solvents and paint sprays.

(h) The Vendor/Contractor shall ensure that personnel employed in the workshop are competently
trained to operate tools and machinery.

(i) The workshop area shall be restricted to personnel assigned to modelmaking, and shall only be
used within designated working hours.

5.3 Location

The workshop shall either be insulated for noise, or located in a place where noise from the workshop does
not distract other occupants of the premises.

6.0 PROGRESS, REVIEWS AND APPROVALS

6.1 Model progress shall be monitored on a model completion curve, that will show scheduled, and actual
completion curves.

6.2 When the model has reached 50% completion, all equipment, steel structures and access roads as a
minimum, should have been located on the model.

6.3 At this stage, the first model review by the Owner shall be made for equipment location and access.

6.4 When the model reaches 90% completion, the model shall be reviewed by all the disciplines within the
Vendor/Contractor's offices, including construction, commissioning Department and Hazop Groups. The
model shall be checked line by line, by the Vendor/Contractor's process department for process integrity
and completeness. The model shall then have all comments incorporated and then worked up to 100%
completion. The Owner will then make a final review of all design aspects of the model.

6.5 The Owner reserves the right to inspect the model or a part of it, at any time, in addition to the above
schedule, provided that sufficient notice is given to the Vendor/Contractor of the Owner's intent.

7.0 PHOTOGRAPHY

7.1 Each base board shall be photographed during progress of the model at 50%, 90% and 100% completion.
The full assembly of the model shall also be photographed upon 100% completion. Photography shall be
carried out using a neutral backcloth, and producing colour photographs, (size 10" x 9").

7.2 The number and angle of camera shots shall be specified by the Owner. Each photograph shall be indexed
and fully identified with the area photographed. Photographing of the model shall be strictly controlled,
and casual or private photography shall not be permitted without the permission of the Owner.
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8.0 PACKAGING AND SHIPMENT

8.1 When the model is 100% complete and ready for shipment to site, each base board shall be carefully
checked to ensure that there are no loose components, and then drop-tested a few inches from the floor to
ensure soundness.

8.2 Each base board shall be packed into custom built wooden crates and protected by packing so that they are
not damaged in transit.

9.0 SITE ASSEMBLY

9.1 The Vendor/Contractor shall unpack and re-assemble the model at the final destination and repair any
damage caused during transit. Repairs shall be made by a professional model maker appointed by the
Vendor/Contractor.

9.2 The model shall be located in a specially designated building and access carefully controlled by
Vendor/Contractor and/or Owner.

9.3 All items which may damage the model such as construction tools, hard hats etc., must be left outside the
model room.

9.4 The model shall be brought to an as-built status after the construction phase at the Owner's discretion.