Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

DGS-MU-012-Rev-1

REQUIREMENTS FOR MANUFACTURING DATA REPORT

FOR NON-PRESSURE VESSEL EQUIPMENT

Amendment History

1 May 2009 AMD-MU-012-001-BECHTEL Section # 2.0 & 6.0 SMK / QAM / May 2009
HD MAY
Clause # 7.1.5, 7.1.7, 7.1.8,
7.1.9, 7.2.1 & 7.2.4

No Date Amendment Description Proposed Approved Incorporated

DGS History

1 May 2009 DGS-MU-012-Rev-1 AMD-MU-012-001-BECHTEL SMK / HD QAM / MAY

0 Mar 2006 DGS-MU-012-Rev-0 Previous Projects SMK / HD ETSDM / EPDM

No Date Description Source Reviewed Approved

Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 1 of 10

 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

TABLE OF CONTENTS

1.0 GENERAL ......................................................................................................................... 3

1.1 INTRODUCTION...................................................................................................... 3
1.2 PURPOSE................................................................................................................ 3
1.3 DEFINITIONS .......................................................................................................... 3
2.0 CODES AND STANDARDS .............................................................................................. 4
3.0 REFERENCE DOCUMENTS ............................................................................................ 4
4.0 DOCUMENT PRECEDENCE ............................................................................................ 4
5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ............................................... 4
6.0 QUALITY ASSURANCE/QUALITY CONTROL ................................................................. 4
7.0 SUBMITTAL REQUIREMENTS......................................................................................... 5
7.1 GENERAL ................................................................................................................ 5
7.2 DOCUMENTS .......................................................................................................... 5
7.3 VENDOR QC DOCUMENTATION AND CERTIFICATION....................................... 6
ADDENDUM SHEET .................................................................................................................. 9

List of Authorized Signatures/ Initials

DGS Discipline Committee Member, ADRD: None

DGS Discipline Committee Member, RRD: Hani Dawod (HD)

DGS Discipline Committee Member Leader, E&PD: Shivaji M. Karade (SMK)

Engineering & Technical Services Manager, E&PD: Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD: Mohamed Al Yabhouni (MAY)

Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 2 of 10

 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

1.0 GENERAL

1.1 INTRODUCTION

1.1.1 Scope

This specification describes requirements for the compilation and submittal of

manufacturing data reports by the VENDORS of equipment other than pressure
vessels. See specification DGS-MD-007 for requirements of manufacturing data
reports for pressure vessels.

1.1.2 Regulatory Considerations

If national and/or local regulations exist in which some of the requirements may be
more stringent than in this specification, the CONTRACTOR shall determine which of
the requirements are the more stringent and which combination of requirements will be
acceptable as regards safety, economic and legal aspects. In all cases, the
CONTRACTOR shall inform the COMPANY of any deviation from the requirements of
this specification which is considered to be necessary in order to comply with national
and/or local regulations.

1.2 PURPOSE

This specification is intended for use in the design and fabrication of the equipment for
the Project.

1.3 DEFINITIONS

For the purposes of this specification, the following definitions shall apply:

DOCUMENT – Any form, letter, facsimile, contract, specification, requisition, drawing,

or record of any kind required to transmit information from one party to another. It also
includes computer generated drawings, lists, charts, etc. and other data used to form a
permanent record of the Project process.

CONCESSION REQUEST - A deviation requested by the SUBCONTRACTOR or

VENDOR, usually after receiving the contract package or purchase order. Often, it
refers to an authorization to use, repair, recondition, reclaim, or release materials,
components or equipment already in progress or completely manufactured but which
does not meet or comply with COMPANY requirements. A CONCESSION REQUEST
is subject to COMPANY approval.

SHALL – Denotes a mandatory action or requirement.

SHOULD – Denotes an action or requirement which is not mandatory but which is

strongly recommended.

Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 3 of 10

 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

2.0 CODES AND STANDARDS

The following codes and standards, to the extent specified herein, form a part of this
specification. When an edition date is not indicated for a code or standard, the latest
edition in force shall apply.

International Organization for Standardization (ISO)

ISO 9001-2000 Quality Management System Requirements

ISO 9004-2000 Quality Management Guidelines for Performance Improvement

System

ISO 19011 Guidelines for Quality and/or Environmental System Auditing

3.0 REFERENCE DOCUMENTS

Not Applicable.

4.0 DOCUMENT PRECEDENCE

It shall be the VENDOR’S responsibility to be, or to become, knowledgeable of the

requirements of the referenced Codes and Standards.

The VENDOR shall notify the CONTRACTOR of any apparent conflict between this
specification, the related data sheets, the Codes and Standards and any other
specifications noted herein. Resolution and/or interpretation, precedence, shall be
obtained from the CONTRACTOR in writing before proceeding with the
design/manufacture.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or

other PROJECT documents as applicable.

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Purchase Order and its attachments including, but not
limited to, the Data Sheets and Narrative Specifications shall be sought by the
VENDOR only through CONCESSION REQUEST format. CONCESSION
REQUESTS require CONTRACTOR’S and COMPANY’S review/approval, prior to the
proposed technical changes being implemented. Technical changes implemented
prior to COMPANY approval are subject to rejection.

6.0 QUALITY ASSURANCE/QUALITY CONTROL

CONTRACTOR’S proposed quality system shall fully satisfy all the elements of ISO
9001 - 2000 and ISO 9004 – 2000 with due regard to ISO 19011. The quality system
shall provide for the planned and systematic control of all quality-related activities
performed during design/development, production, installation or servicing (as
appropriate to the given system). Implementation of the system shall be in accordance
Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 4 of 10
 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

with the CONTRACTOR'S Quality Manual and Project Specific Quality Plan, which
shall both together with all related/referenced procedures, be submitted to COMPANY
for review, comment and approval as required by purchase/contract documents.

7.0 SUBMITTAL REQUIREMENTS

7.1 GENERAL

7.1.1 The Manufacturing Data Report (MDR) for each equipment item shall be compiled in
accordance with the following requirements and the applicable codes.

7.1.2 Documents shall be written in English.

7.1.3 Documents shall be in a legible, reproducible form.

7.1.4 The number of MDR’s to be supplied shall be specified in the request for quotation
(RFQ) and the Purchase Order (PO) documents.

7.1.5 Drawings and other data shall be based on the A4 series sizes, and all drawings larger
than A4 size shall be folded to A4 size and inserted into pre-punched plastic sleeves.
Documents shall be folded so that the title box and status decal are facing.

7.1.6 The contents of the MDR shall be collated into a logical sequence in accordance with
the Purchase Order/Contract requirements and Paragraph 4.3 of this document.
Tabbed dividers shall be provided to separate the sections of data.

7.1.7 Vendor shall submit a detailed MDR index/contents list for CONTRACTOR approval
within 8 weeks of order placement unless stated otherwise in the Purchase Order.

7.1.8 The reports shall be provided in loose leaf form with numbered pages in 2.5 inch
(MANUFATURER/VENDOR can use narrower binders if appropriate subject to
CONTRACTOR approval) hard cover A4 size binders. Binder mechanism shall be four
pillar interlock type. The color and finish of the binder will be advised by
CONTRACTOR/COMPANY during a preproduction meeting.

7.1.9 Multiple binders must be clearly referenced i.e.1 of ..?.., and each contain an index
detailing how many volumes and the contents of each volume.

7.2 DOCUMENTS

7.2.1 As manufacturing of the equipment progresses, the MANUFACTURER/VENDOR shall

compile the MDR with all the design, manufacturing, inspection, tests, and certification
information on a per tag item number basis. Documents that are common to more
than one item shall be duplicated in each report. MANUFACTURER/VENDOR shall
present MDR’s to nominated inspector at each inspection visit. It is also their
responsibility to ensure that Inspection & Test Plans are signed and dated by
nominated inspector on the day of any inspections or tests.

7.2.2 The spine and cover of each binder shall indicate the following as a minimum:
Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 5 of 10
 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

Manufacturing Data Report

Project Name
Vendor Name
Purchase Order No.
Equipment No.
Equipment Description
Vendor Order Ref. No.
Vendor Doc. No.
Date of Issue and Revision

7.2.3 Alterations, deletions, or additions to certification are not normally permitted, and a
new document must be prepared. However where this is not possible the alteration
must be approved, signed and dated. Additions and revisions shall be added to the
documentation, not as a replacement but as an addition to the existing records.

7.2.4 The manufacturing data report shall, after being accepted by clear endorsement of
each page by stamp, date and signature of the nominated inspector, be submitted to
the CONTRACTOR. MDR documents already approved by CONTRACTOR with a
signed and dated endorsement do not require additional endorsement by the
nominated inspector at the MANUFACTURER/VENDOR works. The nominated
inspector shall endorse the index as correct with reference to documents embodied
within the MDR. For multi-page documents the first page (used for approval) shall
clearly state the document total number of pages and each page shall be numbered.
CONTRACTOR can subject to COMPANY approval use dated stamps (without
requirement for signature endorsement) providing stamp is uniquely identifiable to
individual inspectors. The original and the required number of copies shall be
forwarded promptly after the completion of the equipment in accordance with the terms
and conditions of the purchase order. If the order is subject to inspection by
COMPANY/CONTRACTOR, the release note for the acceptance of the equipment
shall only be issued when the manufacturing report, including the required number of
copies, is presented.

7.2.5 The use of colored markers to highlight certificates shall not be permitted.

The use of correction fluids such as Snopake is not permitted.

When test/material certification is called for, these certificates are to be countersigned

by COMPANY/CONTRACTOR.

7.3 VENDOR QC DOCUMENTATION AND CERTIFICATION

7.3.1 Document type code number (example G-1) corresponds to a particular document and
it is required that the VENDOR use these numbers on the tabbed dividers separating
the sections of the report.
Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 6 of 10
 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

The following documents, when applicable, shall be included in the reports.

Doc. Type Code Description

General (All Areas)

G-1 Data Index
G-2 Quality Control Index
G-3 Quality Management Plan
G-4 Inspection And Test Plans
G-5 Signed Off Inspection and Test Plans
G-6 Inspection Release Notes
G-7 ASME Certificates
G-8 Concession Request Log
G-9 Copies Of All Signed Off Concession Requests
G-10 Weight Certificates
G-11 Center of Gravity Certificates
G-12 Sub-Supplier List
G-13 Final Sub-Supplier Detail Drawings
G-14 Noise Test Certification
G-15 Design Data Sheets (Final)
G-16 Nameplate Rubbings
G-17 Painting Procedure
G-18 Site Work Quality Management Plan
G-19 Site Work Inspection And Test Plan
G-20 Signed Off Site Work Inspection and Test Plan

Fabrication (All Areas)

F-1 Weld Procedures & Qualifications
F-2 Welder Qualifications
F-3 Weld Map Including Procedure

NDE-Nondestructive Examination (General)

F-4 NDE Procedures
F-5 NDE Map Including Procedure

NDE (Specific)
F-6 NDE Operator Qualifications
F-7 NDE Certificates/Reports
F-8 Pressure Test Procedures
F-9 Pressure Test Certificates
F-10 Weld Repair Location Map
F-11 Weld Repair Procedures
F-12 Heat Treatment Procedures
F-13 Heat Treatment Charts

Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 7 of 10

 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

F-14 Manufacturing/Forming Procedures

F-15 Material Certification Map
F-16 Material Certification
F-17 Valve Test Certification
F-18 Load Test Procedure, Lifting Points
F-19 Load Test Certification, Lifting Points
F-20 Bolting/Gasket Material
F-21 Hydro-Test Water Quality Certificate
F-22 NACE Certificate of Conformance (MR0175)

Machinery
M-1 Casting NDE Procedure
M-2 Casting Repair Procedures
M-3 Casting Manufacturing Procedure Including Minor/Major Repair

Tests
M-4 Balance Test Procedure
M-5 Balance Test Certification
M-6 Vibration Test Procedure
M-7 Vibration Test Certification
M-8 Functional/Performance Test Procedure
M-9 Overspeed Test Procedure
M-10 Overspeed Test Certification
M-11 Functional/Performance Test Certification

Electrical
E-1 Completed Motor Data Sheets By Motor Vendor
E-2 Hazardous Area Certification
E-3 Manufacturing Test Procedures
E-4 Final Test And Insulation Certification
E-5 Functional Test Procedures
E-6 Functional Test Certification

Instrumentation (All Areas)

I-1 Hazardous Area Certification
I-2 Manufacturing Test Procedures
I-3 Manufacturing Test Certification
I-4 Software Verification Certification To IEEE Requirements
I-5 Functional Test Procedures
I-6 Functional Test Certification
7.3.2 The MDR shall contain only those sections which are applicable to the Equipment or
item of material being supplied.

Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 8 of 10

 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

ADDENDUM SHEET

All revisions to this DGS subsequent to the issue of Rev Zero shall be recorded in this addendum
sheet and shall be incorporated into the DGS in the next revision.

Date Proposed Revision Remarks

May 2009 In Section # 2.0: Incorporated in

Revision 1
International Organization for Standardization (ISO)

Replace “ISO 9011” with “ISO 19011”

In Section # 6.0:

Add at the end of first sentence “with due regard to ISO 19011”

In Clause # 7.1.5:

Add at the end “Documents shall be folded so that the title box
and status decal are facing”

In Clause # 7.1.7:

Add at the end “unless stated otherwise in the Purchase Order.”

In Clause # 7.1.8:

Add after 2.5 inch “(MANUFATURER/VENDOR can use

narrower binders if appropriate subject to CONTRACTOR
approval)”

Add new Clause # 7.1.9:

“Multiple binders must be clearly referenced i.e.1 of ..?.., and

each contain an index detailing how many volumes and the
contents of each volume.”

In Clause # 7.2.1:

Add at the end “MANUFACTURER/VENDOR shall present

MDR’s to nominated inspector at each inspection visit. It is also
their responsibility to ensure that Inspection & Test Plans are
signed and dated by nominated inspector on the day of any
inspections or tests.”

Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 9 of 10

 Abu Dhabi Oil Refining Company

REQUIREMENT FOR MANUFACTURING DATA REPORT DGS-MU-012

FOR NON-PRESSURE VESSEL EQUIPMENT Rev-1 May 2009

In Clause # 7.2.4:

Add after first sentence “MDR documents already approved by

CONTRACTOR with a signed and dated endorsement do not
require additional endorsement by the nominated inspector at the
MANUFACTURER/VENDOR works. The nominated inspector
shall endorse the index as correct with reference to documents
embodied within the MDR. For multi-page documents the first
page (used for approval) shall clearly state the document total
number of pages and each page shall be numbered.
CONTRACTOR can subject to COMPANY approval use dated
stamps (without requirement for signature endorsement) providing
stamp is uniquely identifiable to individual inspectors.”

Takreer DGS-MU-012-Rev-1 May-2009 Printed 30-Jun-09 09:34:40 Initials Page 10 of 10