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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
Purpose
To define the requirements in technical standards for design and construction that have
a direct relationship to Process Safety.
Assets owned or operated by a Joint Venture in which Shell does not have a
Controlling Interest, if the Joint Venture partners adopt this Manual following
promotion by the Shell Shareholder Representative as stated in JV HSSE
Requirements;
contracted 3rd party Assets, including temporary boilers, liquid nitrogen storage,
and power generators; and
land transport activities by vehicles used to transport Hazardous Substances.
Defined terms can be found in the HSSE & SP Control Framework Glossary. 1
This document is not controlled when printed. See the Change Log for version control information.
Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
Requirements
The Asset Manager, Project Manager or Wells Manager is Accountable for requirements 1
to 4 below.
1. Apply the mandatory Process Safety Design and Engineering
requirements in the Shell Design and Engineering Practices (DEPs)
listed in Table 1 whenever designing or constructing New Assets or
making permanent or temporary Modifications to existing Assets.
1.1 For projects with a Project Headline Size less than $100 million (100%
project cost) that do not involve Unusual Risk, and for which the DEPs
are not practicable, apply other recognised industry standards or
Company legacy standards. In case of such Derogation from DEM1, the
Delegated Technical Authority must approve the use of alternative
standards, based on a documented risk assessment that demonstrates
that Process Safety risks are managed to ALARP. If alternative standards
are non-existing, use a documented Risk assessment methodology.
Include the documented Risk assessment with the Derogation request for
approval by the Delegated Technical Authority.
1.2 Process Safety requirements in DEM1 DEPs, which refer to requirements
in other Group documents, are only mandatory if the referenced Group
document is mandatory. When Process Safety requirements in DEM1
DEPs refer to requirements contained in external industry codes and
standards those requirements are also treated as mandatory.
1.3 Send a request for Derogation to the Delegated Technical Authority, if
and when a variance to mandatory DEP requirements is observed or
anticipated, including those invoked by 1.1.
1.4 Capture in the Derogation logs of the Assets or projects, for continuous
improvement and for Risk awareness, Derogations from mandatory DEP
requirements.
1.5 The project Derogation log must be transferred to the Asset Derogation
log upon project completion.
1.6 Derogation from the application of Design and Engineering Manual 1
(DEM 1) in its entirety for Assets owned or operated by a Joint Venture in
which Shell does not have a controlling interest, and where the Joint
Venture partners have adopted this Manual, requires approval by those
Joint Venture partners.
2. Apply the edition of the DEM1 DEPs that is valid at the time of end of
Select (Decision Gate 3) for design of a new Asset or modification to an
existing Asset.
3. Approve at the end of Select (Decision Gate 3) how and where to apply
Design and Engineering Manual 1 (DEM 1) to existing Assets affected by
the project.
4. Confirm that the Process Safety requirements in the mandatory DEPs
are met for the construction of new Assets and the modification of
existing Assets.
4.1 Maintain the Derogation Log for the Asset.
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
DEPs shaded orange are those which have remained from the previous revision of Design
and Engineering Manual 1 (DEM 1). Many mandatory requirements within these DEPs
have been revised.
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
DEPs shaded green are those which have been added by this revision.
DEPs are available at http://sww.shell.com/standards/
A phased approach has been used for the development and implementation of Design
and Engineering Manual 1 (DEM 1). Further revisions to this manual will be based on
rationalization with local standards along with regular DEP updating and streamlining
processes.
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Process Safety Manual Restricted
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Shell HSSE & SP Control Framework Mandatory
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DEP-31.29.00.33-Gen. Feb. 2011 Shaft sealing systems for centrifugal and rotary
pumps (amendments/supplements to ISO
21049:2004)
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
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DEP-31.29.70.32-Gen. Feb. 2011 Gas turbine combustion air intake and exhaust
systems
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
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DEP-31.40.20.34-Gen. Feb. 2011 Welded and seamless duplex and super duplex
stainless steel line pipe
(amendments/supplements to API Spec 5LC)
DEP-31.40.20.36-Gen. Feb. 2011 Weldable martensitic stainless steel line pipe for
use in oil and gas operations
(amendments/supplements to API spec 5LC)
DEP-31.40.21.34-Gen. Jun. 2007 Carbon and low alloy steel pipeline flanges for
use in oil and gas operations
(amendments/supplements to ISO 15590-3)
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DEP-31.51.10.31-Gen. Dec. 1998 Side-entry mixers for storage tanks and vessels
DEP-32.00.00.12-Gen. Dec. 2008 Fiscal and sales allocation models for upstream
production systems
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DEP-37.05.10.11-Gen. Dec. 1998 Diesel oil systems in oil and gas production
facilities
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
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DEP-37.81.10.10-Gen. Feb. 2011 Generic design and analysis for steel catenary
risers and catenary umbilical systems for
offshore structures
DEP-37.91.20.30-Gen. Aug. 2005 Oil loading and discharge hoses for offshore
mooring installations (amendments/supplements
to OCIMF Guide)
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
DEP-38.80.20.30-Gen. Nov. 2006 Specifications for cements and materials for well
cementing (endorsement of ISO 10426-1)
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
DEP-38.80.40.30-Gen. Aug. 2005 Steel drill pipe with weld-on tool joints
(amendments/supplements to ISO 11961)
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
DEP-39.01.20.31-Gen. Dec. 2000 Care and use of casing and tubing (endorsement
of ISO 10405)
DEP-39.01.20.34-Gen. Dec. 2004 Field inspection of new casing, tubing and plain-
end drill pipe (Endorsement of ISO 15463)
DEP-61.38.10.10-Gen. Apr. 2006 Shop and field fabrication of orifice meter runs
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Process Safety Manual Restricted
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DEP-80.45.10.10-Gen. Feb. 2011 Design of pressure relief, flare and vent systems
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DEP-80.47.10.31-Gen. Feb. 2011 Active fire protection systems and equipment for
onshore facilities
Implementation Deadlines
Projects before DG3 on 1st of July 2011 are expected to use v7 DEM1 DEPs.
Projects beyond DG3 on 1st of July 2011 may chose to do gap assessments of their
existing design and engineering standards against the v7 DEM1 DEPs.
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
Application of the DEM1 DEPs remains part of the Process Safety audit scope.
All DEM1 (v7) DEPs will be in scope for audit from 1st of July 2011 onwards.
For newly added DEM1 DEPs, audit will be done against Work in Progress criteria
(e.g. resourced plan, well underway) until 31 December 2011
Businesses may choose to do gap assessments of their existing design and engineering
standards against the new DEM1 manual.
Background
While process safety incidents are rare, we know about their potential to cause injury
and even death, as well as damage to the environment, our business and our reputation.
Avoiding a major process safety-related incident within our asset base is a priority and
requires a Group-wide approach.
The HSSE & SP Standards are part of the HSSE & SP Control Framework and are
applicable across all businesses for ventures under operational control. The HSSE & SP
Control Framework gives line management practical tools to help with risk identification,
drives the implementation of associated controls and provides the means to assess the
effectiveness of these controls.
DEM1
DEM1 is a supporting document for the HSSE & SP Standards. It includes a list of DEPs
that specify the mandatory Process Safety requirements needed to manage RAM RED,
5A or 5B process safety risks for design and construction.
In order to complete the verification of the process safety requirements, there will be a
phased transition for DEPs to become listed in this Design and Engineering Manual,
DEM1.
Phase 2: Review all DEPs and issue of 126 DEM1 DEPs on 1 March 2011.
Phase 3: Review remaining regional and local standards such as EGGs, ESTGs,
SEPCo Engineering Standards, and EP Well specific design manuals, etc. during
rationalization with the DEPs.
This activity will be incorporated into the three (3) year DEP restructuring plan. Any new
DEM1 DEPs resulting from this activity will follow the process for adding a DEP to DEM1.
This activity will be complete by 31 December 2012.
This manual will subsequently be reviewed and updated if required, on an annual basis.
If you have any queries regarding the Design and Engineering Practices or the HSSE
Control Framework, please contact:
Margaret Sargent, PTE/DTST, Shell Standards Manager
Arjan van Dijk, PTS/S, VP Safety
Paul Buijsingh, PTE/D, Manager Process Safety
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Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 7, May 2011
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